Prepping the Machine for Operation
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The Floorpocket, like all of Creative Conners, Inc.’s hoisting equipment, has a redundant set of brakes as a safeguard against a brake failure. There is one brake located on the motor side of the machine and the other brake is located on the load side of the machine.
The motor brake is a small, fast-acting brake that holds the motor shaft in place when the machine is stopped. The motor brake uses the mechanical advantage of the speed reducer (aka gearbox) to increase its holding ability. The Stagehand Pro AC expects that the motor brake will be fully released 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 removed, the motor brake will engage by spring force. This is a “fail-safe” brake, it fails to a safe condition by engaging when power is lost. Not all machines explicitly require a motor brake, but we recommend using motor brakes in all applications. All of Creative Conners, Inc.’s machines are built with a motor brake.
In lifting applications, a second brake is required to provide redundant protection in case of equipment failure. Often, this second brake is placed directly on the output side of the speed reducer. If either the speed reducer or the motor brake fails, a brake on the load side of the machine will be able to stop a falling load. The Stagehand Pro AC expects that the load brake will be fully released within 500ms of receiving power.
If a brake is used on the output side (aka load side) of a speed reducer, then it must be much larger than the motor side brake since it isn’t able to use the mechanical advantage of the speed reducer to increase its holding power. Load brakes are not required on all machines. The additional expense is often not incurred for machines that are moving scenery laterally. For instance, our Pushstick deck winch does not have a load brake, but our Spotline hoist does use a load brake.
Having two brakes is a good thing, but you might ask how do you know if a brake fails when the other brake is still operating correctly? We had this thought too. This is why we now include a brake test feature on our Stagehand Pro AC. Before operating the machine and during your nightly pre-show check, you should perform a brake test to ensure that both brakes are operating correctly.
Clear the area around the lift. If a brake were to have failed, the lift platform could fall during this test.
Press the Brake Test Enable Button
While holding the Brake Test Enable Button, press the Load Brake Button. This will manually release the Load Brake. The Motor 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 has failed.
DO NOT OPERATE THE MACHINE UNTIL THE MOTOR BRAKE IS REPAIRED OR REPLACED. FAILURE TO REMOVE THE MACHINE FROM SERVICE COULD RESULT IN DAMAGE, INJURY, OR DEATH.
Provided the Motor Brake passed the functional test, release the Load Brake button.
While holding the Brake Test Enable Button, press the Motor Brake Button. This will 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 did not hold the load as expected, that brake has failed.
DO NOT OPERATE THE MACHINE UNTIL THE LOAD BRAKE IS REPAIRED OR REPLACED. FAILURE TO REMOVE THE MACHINE FROM SERVICE COULD RESULT IN DAMAGE, INJURY, OR DEATH.
Release the Motor Brake Button
Pro Tip: If you press all three buttons at once, both brakes will engage
To confirm that your motor is properly connected to the Stagehand Pro AC you should test these conditions:
E-Stop – Release the E-Stop button on your Showstopper. You should hear a “click” from inside the Stagehand, this is the E-Stop contactor closing. The OLED display should show that the E-Stop is released by changing the status display; “Not Connected” indicates that the Stagehand Pro AC is not communicating with a computer running Spikemark.
Brake release – Press the FWD jog button. You should hear a distinct “click” from your redundant brake quickly followed by the motor brake. This is the sound of the brake releasing. Release the FWD job button. You should hear a click of the brakes engaging.
Motor Motion – Press the FWD jog button and slowly turn the knob clockwise. The lift should begin moving upwards. Turn the knob counterclockwise to slow the lift to a stop, then release the jog button. Repeat with the REV jog button and verify that the lift moves downwards.
Encoder – When jogging the motor the OLED will display the encoder counts. While jogging the motor, verify the counts are increasing while running in the forward direction and decreasing while running in the reverse direction.
Limit Switches – Manually activate the forward ultimate limit and the forward limit then activate the reverse ultimate limit and reverse limit. The OLED display on the Stagehand Pro AC should indicate when the corresponding limit is detected.
Each limit is attached to its own track to adjust the position at which the limit is triggered. To adjust your limits, loosen the socket head cap screw attaching the limit to the track with a 5/32” hex key, slide the limit up or down its track, and resecure the socket head cap screw. The FWD and REV limits are there to prevent your Floorpocket from getting damaged. The FWD ULT and REV ULT limits are set behind their initial limits for redundancy to prevent your Floorpocket from getting damaged if your FWD or REV limit does not trigger the stop in motion. If you are installing an extension tower onto your Floorpocket, you will need to attach the FWD and FWD ULT limit tracks to the ModTruss tower with the included 5/8” Grade 8 hex head bolts, washers, and nuts.
The following is a checklist to inspect the Floorpocket prior to operation. It is necessary to perform the checklists detailed below to ensure all components of the Floorpocket are operating correctly. If any component fails the test, do not use the Floorpocket and consult Creative Conners, Inc.
Confirm all structural/mechanical connections are secured to the proper torque settings.
Confirm the base frame is level.
Confirm gear rack and linear rail alignment.
Confirm the platform is level.
Confirm the platform is rigid and stable.
Inspect gear rack and pinion for excessive wear.
Lubricate gear rack and pinion.
Recommendation: Microlube GB 0, Mobilux EP 111
Confirm rack safety guard is installed.
Confirm safety guards above and below guide rollers are installed.
Confirm the Floorpocket can jog in both directions.
Confirm the Stagehand Pro AC is receiving encoder signals.
Position value should increase while lift moves FWD/upward.
Position value should decrease while lift moves REV/downward.
Confirm theStagehand Pro AC displays proper limit information when limit switches or safety bumpers are engaged.
FWD Limit
FWD limit at top of travel
Halo safety edge
Ultimate FWD Limit
ULT FWD limit at top of travel
REV Limit
REV limit at bottom of travel
Platform bumper edge
Safety mat
Ultimate REV Limit
ULT REV limit at bottom of travel
Confirm brake operation with brake test sequence.
Run brake test sequence.
Connect the Stagehand Pro AC to Spikemark.
Confirm current position
Confirm safety mat and safe edge is connected and functioning.
Check Limit Placement/Operation.
FWD Limit
Physical switch at the top of travel
Halo safety edge
ULT FWD Limit
Physical switch at the top of travel
REV Limit
Physical switch at the bottom of travel
Platform bumper edge
Safety mat
Ultimate REV Limit
ULT REV limit at the bottom of travel
Confirm smooth operation over the entire range of motion.
Run a test cue in Spikemark, confirming that all safety interlocks are functioning correctly and target position is achieved.