Rigging the Spotline

Setting the Limits

Before you can rig the Spotline in any configuration, you need to know how to adjust and set the limits. The Spotline includes four (4) limits: FWD-ULT, FWD, REV & REV-ULT limits. All four limits are adjusted from the rotary limit switch mounted to the Spotline frame. The limits should be used as Overtravel Limits. During normal cue control operation the limits should not be struck, they are intended to halt motion if there is a failure.

The rotary limit has 4 layers, each layer includes a CAM lever and a micro-switch to activate the individual limit. When the Spotline is moving in REV the limit stack is rotating Clockwise.

The limit stack rotates Counter Clockwise when moving FWD.

To adjust the limits, remove the cover to expose the limit switch stack. You will see 5 screws on the top of the stack. The center screw is the locking screw, which locks the layers in place relative to each other. The four smaller screws around the outside are used to adjust each of the individual switch CAM’s. Each adjustment screw has a number next to it, which corresponds to which layer it adjusts. Turning the adjustment screw CW will move the CAM CW.

Before moving the machine, it is advised to open the rotary limit box and confirm the CAM’s are all positioned correctly to allow enough movement to rig the winch. Because we will be rigging the drum by jogging the machine in REV, both the REV and REV-ULT CAM’s should be located “above” the micro switch column. The FWD and FWD-ULT CAM’s should be “below” the switch column.

Since pictures are worth 1000 words, check out this cool slideshow about setting the limits.

Single Point Hoist Rigging

After you have assured the Spotline is functioning properly, the Spotline can be rigged. The Spotline can have the cable enter and exit from all sides of the drum. It is important the cable keeper is mounted as close as possible to the cable exit path to allow for the correct cable entrance and exit. The directions below will guide you through rigging the Spotline for a single point pick. The figure below is a schematic drawing of the rig.

Figure 2.1

  1. Place a spool of 7X19 ¼”wire rope next to the piece of scenery that will be lifted by the hoist.

  2. Run the end of the cable through all of the necessary pulleys and into the hoist. The fleet angle of the wire rope off the drum cannot exceed 2 degrees.

  3. Run the wire rope through the hole drilled in the drum on the “brake side”. Terminate the wire rope with a NicoPress stop sleeve in the drum. Use the termination as per the manufacturer’s guidelines.

  4. Using the Stagehand Pro AC, slowly move the motor FWD with the manual jog controls. The cable should begin to wind up onto the drum. Note: Keep tension on the cable throughout this process.

  5. Take a minimum of 3 safety wraps on the drum.

  6. Decide how much extra travel is needed when piece of scenery would need to be at its lowest position possible and add those wraps. (1 Wrap = 25”).

  7. Cut the wire rope from the spool and now attach it to your piece of scenery.

  8. Using the Stagehand Pro AC slowly move the piece of scenery to its highest position to ensure the cable piles on the drum properly.

  9. With your piece of scenery in its highest safe position set the Ultimate FWD limit.

  10. Then move your piece to the highest you would move it on a daily basis and set the FWD limit.

  11. Fly the piece of scenery in to its lowest safe position and set the Ultimate REV limit.

  12. Then move your piece to the lowest you would move it on a daily basis and set the REV limit.

Your Spotline is now ready to FLY!

Since pictures are worth 1000 words, here's a slideshow dedicated to rigging a Spotline

Deck Winch

The Spotline can be easily rigged as a deck winch with the addition of the Spotline Tensioner. Although it is not required, it is best practice to follow the same brake and limit testing procedures when using the Spotline as a deck or track winch. Once you have assured the Spotline is functioning properly, the machine can be rigged. When rigged as a deck winch with the Spotline Tensioner, both ends of the line will feed through the Tensioner and terminate to the drum. The directions below will guide you through the process of rigging the Spotline and Spotline Tensioner for use as a deck or track winch. The figure below is a typical schematic view of the rigging.

  1. Install the Spotline Tensioner with 4 (four) cheesebouroughs.

  2. Confirm tensioner pulley assembly is run fully to the side of the Tensioner with the flat stock (the exit position)

  3. Place the spool of 7x19 aircraft cable in front of the Spotline on the Gearmotor side.

  4. With the spool of cable able to spin freely, feed the end of the wire rope through the system.

  5. Do not forget to install the Dog while at this time.

  6. With the free end of the rope run through the system and back at the Spotline, feed it through the tensioner pulley, and terminate it inside the BRAKE side of the Spotline drum.

  7. Terminate the wire rope in accordance with the manufacturer’s specification.

  8. Jog the Spotline in REV to begin spooling cable onto the drum, so you end up with three (3) dead wraps on the drum.

  9. The cable should wind into the grooves and under the cable keeper.

  10. Continue wrapping the drum with cable until you have added enough cable to complete your move

  11. Continue spooling on four (4) additional wraps.

  12. This will give you your remaining three (3) dead wraps along with a little extra insurance

  13. Unspool and cut enough wire rope to run through the remaining tensioner pulley and to terminate through the motor end of the drum.

  14. Feed the free end through the drum and terminate inside the drum.

  15. Remove as much slack as possible when making this termination.

  16. We find it easiest to use a Fist Grip cable grip for this termination.

  17. Trim any excess wire rope

  18. Slide dog along the wire rope, a minimum of 6’-0”.

  19. Using the 2 tension nuts, take us as much slack as possible by hand.

  20. Jog the machine FWD until there are 3 dead wraps on the motor side of the drum.

  21. Adjust the position of the dog and lock it to the wire rope with the four set screws.

  22. At this point you will only be able to jog the Spotline FWD to maintain the 3 wrap minimum on the drum.

  23. Using an 1-1/8” wrench take up as much tension as possible between the 2 tensioning nuts.

  24. The pulley shaft should be kept as parallel as possible with the drum.

  25. Jog the Spotline to the max FWD travel position.

  26. Remove the limit box cover

  27. Loosen the center locking screw half a turn.

  28. Adjust both the FWD and FWD-ULT cams to the BOTTOM of the switch stack.

  29. The FWD cam should be just activated in this position. The FWD-ULT is just behind it.

  30. Tighten the locking screw.

  31. Jog the Spotline to the max REV travel position and loosen the center locking screw.

  32. Adjust both the REV and REV-ULT cams to the TOP of the switch stack, following the same guidelines as above.

  33. Tighten the locking screw

  34. Test the limits by jogging the machine, adjust as necessary.

Your Spotline and Spotline Tensioner are now ready to roll!

Is this too many words? Would you like more pictures? Check out this slide show about rigging a Spotline and Tensioner to use as a deck winch:

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