Daktronics S SERIES User Manual

S SERIES OPERATION & MAINTENANCE MANUAL

S SERIES OPERATIONS MANUAL

Daktronics Automated Rigging System

Manufacturer’s contact info

7200 Rawson Road

Victor, New York 14564

tel [phone]
fax [phone]

email [e-mail]

web site www.daktronics.com/rigging

TABLE OF CONTENTS

01 Theory of Operation ................................................................................ 01

Vortek S-Series Controller

Movements of the hoist
Power supply

02 Batten and Hoist Loading Information .........................................................02

Uniformly distribute loads

Understanding stage rigging

03 Motorized Batten Hoists ............................................................................ 02

Hoist unit composition

Patented load brake
VSC and the hand-held pendant controller

04 Daktronics S Series Controller .....................................................................04

Description
Operation
Recommended procedures

05 Troubleshooting Guide......................................................................................06

Symptoms

Causes
Corrective strategies

06 Maintenance Guide...........................................................................................07

07 Warranty ................................................................................................ 17

One year warranty

Responsibilities under warranty
Compliance with warranty

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TABLE OF CONTENTS

01 THEORY OF OPERATION

Each Vortek hoist is connected to the main high voltage power buss through a safety twist­locking plug. This plug brings in the main 208 or 480 VAC (refer to system riser), 3-phase
power that is connected to the motor contactors and motor brake located in each hoist
assembly. The high voltage power originates in the Master Control Cabinet (MCC). Also
connected to each Vortek hoist assembly through a safety locking connector are 24-volt DC
control and E-Stop circuit.

The reversing contactors control all movements of the hoist. Each S Series controlled
hoist with Push Button Control runs in open loop and is controlled at the main MCC via
momentary push buttons. Each hoist is protected via hardwired UP and DOWN control
signals, hard struck limit switches, emergency stop status and optional over/under capacity
sensors. The UP and DOWN control signals determine which contactor to energize for
direction to run the hoist (Figure 1). The limit switches are used for maximum up and
down travel. The emergency STOP status is used to detect the operation of the emergency

stop system and the
optional over/under
capacity sensors will
ensure that the hoist is
being operated within its
designed capacity.

Housed within the MCC
is a 24-volt DC power
supply that powers the
control circuit and the
E-Stop circuit. A fused
disconnect and a master
control contactor are also
mounted inside the MCC.
The 24-volt DC E-Stop
circuit is connected to the
E-STOP button located
on the front of the master

FIGURE 1: S Series Control panel

applicable.

control cabinet as well as
the E-STOP button located
on the pendant, if

THEORY OF OPERATION

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02 BATTEN AND HOIST LOADING INFO

Uniformly distribute loads.
Ensure loads are applied to 2 or more lift lines.

• Max. 1500 Pounds Total Applied Load Per Winch

• Maximum live load design capacity on each batten = 30 Pounds Per Linear Foot

• Do Not Concentrate Full-Capacity Point Loads on One Lift Line

Daktronics strongly recommend a thorough understanding of stage rigging practices
before any changes are made to batten loads. Many reference sources are available
that contain important information that will allow you to safely hang heavy loads
once you understand the limitations and dynamics of the materials used in rigging:
wire rope, pipe battens, etc.

03 MOTORIZED BATTEN HOISTS

The Vortek hoist system is a dead-haul system meaning that the load is not counter­weighted. 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 unit 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 the lower hard struck limit to allow attachment of loads. Refer to
installation drawings for the exact location and dimensions.

Warning:

The VORTEK Batten Hoists are not designed to raise and
lower people. These hoists should NEVER be used for

this purpose.

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The Vortek S Series Hoist System consists of three basic parts:

1. The S Series controller - where the operator controls the system.

2. The Vortek hoist wireways - connect the controls to the
hoists themselves.

3. The Vortek hoist units - completely self-contained electrical and
mechanical equipment.

1. The hoist power panel assembly is located at the end of each Vortek motorized
hoist (the blue box at the end where the HV and LV cables plug in). There is a
resettable circuit breaker located at each power outlet on the High Voltage
wireway that also serves as a safety disconnect. The rated twist-locking plug on
each unit also acts as a main (local) high voltage disconnect.

2.

The Vortek hoist units are mounted on structural steel, usually at the top of the
stage house (refer to your project installation drawings for exact placement of the
hoist units). The gear motor, helically grooved cable drum, support bearing and
frame structure are all factory assembled and tested. On each hoist assembly
is one set of hard struck limit switches. These limits are the upper ultimate limit
and lower ultimate limit. These limit switches are adjusted by factory-trained
personnel at the factory test and are fine tuned on site by the installer during
installation and commissioning of the system. There is also one set of over travel
limits. Each hoist assembly is also equipped with our PATENTED LOAD BRAKE,
a unique safety feature provided exclusively by Daktronics. This brake is a
fully-mechanical, always engaged drive-through secondary brake. This greatly
reduces any possibility of a loaded batten to descend uncontrolled.

3. Control of all hoists is possible from the S Series controller or hand-held
pendant controller, located such that a clear line of site can be achieved.

4. The controller contains the main system disconnect, master control contactor,
control voltage power supply and control buttons.

5. 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.

MOTORIZED BATTEN HOISTS

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04 S SERIES CONTROLLER

Description:

The Daktronics S Series Controller is the most economical form of control available and should be
selected only if precise positioning and speed control is not required. The MCC will contain an “UP/
OFF/DOWN” switch for each Vortek hoist on the system, a main “Power On” key switch, one master
“RUN” button, an “Emergency Stop” button located on the bottom of the MCC, and indicator lights
for “POWER ON”, “OVERTRAVEL FAULT”, “OVERSELECT FAULT”, and “VOLTAGE/PHASE FAULT”.
A lockable main power disconnect handle will also be accessible on the front of the MCC for the
removal of all power from the system. The optional handheld pendant controller will contain “RUN”
and a locking “Emergency Stop” buttons along with indicator lights for “ACTIVE” and “Emergency
Stop”. The handheld pendant should be used where proper Line-of-Site is not feasible from the

location of the MCC.

Operation:

To power up the system:

Turn on the main disconnect switch located on the front of the master control cabinet and then turn
the key switch on. The green power light should now be illuminated. If the green power light does
not illuminate, check to make sure that the E-Stop button are not pressed.

If the red light stays illuminated, then one of the over travel limits has been engaged. Contact
Daktronics for instructions on resolving this issue.

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