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On this page
  • Getting Started
  • What’s Included
  • Features
  • Installation
  • Powering Up
  • Interlock Connections
  • Interlock Input
  • Interlock Output
  • Interlock Terminator
  • DISCREET INTERLOCK INPUTS
  • Safety Sensor Connections
  • Operation
  • Troubleshooting
  • Common Problems
  • Technical Support
  • ELECTRICAL SPECIFICATIONS
  • Power Input
  • Low Voltage Fuse
  • Interlock Input
  • Interlock Output
  • Forward Interlock Input
  • Reverse Interlock Input
  • All Stop Interlock Input
  • External Fault Input
  • Reverse Interlock Input
  • Forward Interlock Input
  • All Stop Interlock Input
  • Reverse Sensor Input
  • Reverse Sensor Output
  • Reverse Sensor Signal
  • Forward Sensor Input
  • Forward Sensor Output
  • Forward Sensor Signal
  • Drawings

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  1. Showstopper
  2. Safety Interlock

4-Axis Safety Interlock

REFERENCE MANUAL v1.0

PreviousSafety Interlock Pro 4NextLegacy

Last updated 6 months ago

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Getting Started

The Safety Interlock is an extra layer of safety to critical effects. Integrating bumper switches, pressure mats, and additional limit switches into any system gives a secondary layer of protection for areas with potential pinch points, like an elevator or pivoting wall.

A lift requires many safety features to keep everyone safe. These additional systems include bumper switches and auxiliary limits to interlock other effects, which are incorporated through the 4-Axis Safety Interlock.

The 4-Axis Safety Interlock is connected between four Stagehand Pro 4s and the 4-Post Lift, reading signals from the safety sensors and interrupting motion if any safety sensor is activated.

This manual will guide you through:

  • Unpacking

  • Installation

  • Powering up

  • Operation

  • Troubleshooting

What’s Included

In the box you will find:

  • Safety Interlock Control - 4-Axis

  • Two 3-pin XLR jumpers

  • Three interlock jumpers (same ML-1 connector as limit jumpers)

  • Locking IEC power cable

If any of these parts are missing, please contact us.

If you ordered any bumper switches or pressure mats those items are packaged separately.

Features

The Safety Interlock Pro is a 3U rack mountable device with 4 mounting holes.

Description of connections of 4-Axis Interlock, per labeled images above:

  1. Power indicator light

  2. Status indicator lights, if the light goes out there is a fault state to be addressed.

  3. Sensor override button allows you to momentarily jump out a struck sensor so that you can jog or run a cue away from the triggered sensor.

  4. Input power connector (fused), locking IEC.

  5. Fuse protection for low voltage circuitry

  6. Interlock cable inputs and outputs for up to (4) Stagehand Pro 4s.

  7. Discreet Interlock inputs

    1. ML1 receptacles are used for the interlocks

  8. 4-Wire Sensor Inputs/Outputs

    1. 3-pin XLR connectors are used for sensors (at minimum your bumper switches).

There are 5 sets of safety devices that can be connected with the 4-Post Lift and the 4-Axis Safety Interlock.

  1. Reverse Sensor, Platform Bumper Switches

  2. Forward Sensor, Static Bumper Switch

  3. Reverse Interlock, use for interlocked effect that would be harmed by DOWN motion of the lift

  4. Forward Interlock, use for interlocked effect that would be harmed by UP motion of the lift; e.g. a sunroof

  5. All-Stop Interlock, halts motion in all directions; can be used to integrate a dead-man switch for all connected Stagehands

Installation

The Safety Interlock Pro 4 is a 2U rack mountable case designed to fit in a standard 19” rack. It is not required to be rack mounted, so feel free to place it on the operator desk or with the Stagehand Pro 4 motion controllers.

Keep in mind that the Safety Interlock Pro 4 will need to be connected between the machine and the Stagehand, be sure to plan your location (and cables) accordingly!

Powering Up

After the Safety Interlock is installed, it is time to power it up and test that bumper switches, pressure mats, and/or limit switches are working correctly. The Safety Interlock Pro 4 requires 24VDC from the Stagehand Pro 4 in order to receive power.

Interlock Connections

There are four basic connections that you need to be concerned with on the Safety Interlock Pro 4:

  • Interlock Input

  • Interlock Output

  • Discreet Interlock Sockets

  • Sensor Inputs

Interlock Input

The Interlock Input on the Safety Interlock Pro 4 connects directly to the Stagehand Pro 4 Interlock Input. Notice how the Stagehand has a female connector and the Safety Interlock has a male connector.

Interlock Output

The Interlock Output provides four (4) sensor inputs that can interrupt motion to avoid collisions.

Two machines may present a hazard on stage when they obstruct each other's path. The interlock inputs allow the Stagehand to sense an external obstruction and abort motion if the path is not clear. Interlock faults are shown on the Stagehand Display, and within the Spikemark software, to easily identify the culprit when motion stops unexpectedly.

Switches wired into the Interlock Connector are often wired Normally Open (N.O.) leaving the circuit open until the switch is activated by a scenic element moving into a safe position.

When automating a lift with a trap door, the lift should not move upward until the trapdoor is fully open. In such a scenario, a limit switch can be physically affixed to the trap door to sense the position of the door, but the switch can be wired to the Forward Interlock input of the lift to prevent the lift colliding with the trap door.

Interlock Terminator

Any unused Interlock Outputs must be terminated. Without the terminators installed, the Interlock will be in a fault state.

Forward Interlock

Forward movement is interrupted unless +24VDC is sensed on pin #2 of the Interlock Connector. If motion is interrupted, either clear the obstruction or temporarily override the interlock signal by plugging in the Interlock Terminator that was shipped with the Stagehand Pro 4.

The Forward Interlock can be used much like a Forward Limit, but rather than limiting forward motion based on the position of the machine powered by the Stagehand, the Forward Interlock senses the position of another machine or scenic element.

Reverse Interlock

Reverse movement is interrupted unless +24VDC is sensed on pin #3 of the Interlock Connector. If motion is interrupted, either clear the obstruction or temporarily override the interlock signal by plugging in the Interlock Terminator that was shipped with the Stagehand Pro 4.

The Reverse Interlock can be used much like a Reverse Limit, but rather than limiting reverse motion based on the position of the machine powered by the Stagehand, the Reverse Interlock senses the position of another machine or scenic element.

All-Stop Interlock

Both forward and reverse movement are interrupted unless +24VDC is sensed on pin #4 of the Interlock Connector. If motion is interrupted, either clear the obstruction or temporarily override the interlock signal by plugging in the Interlock Terminator that was shipped with the Stagehand Pro 4.

External Fault Input

DISCREET INTERLOCK INPUTS

The Stagehand Pro 4 and up motion controller monitors forward, reverse, and ultimate limit circuits just like previous Stagehands, but also adds new discrete circuits for monitoring Forward, Reverse, and All-Stop interlocks. The interlock connections on the 4-Axis Safety Interlock allows added switch connections that will be propagated to all connected Stagehands.

The Discreet Interlock Inputs utilize the same ML-1 connector as CCI traditional limits. Essentially, they do the same thing as in the Interlock Output but allow for easier wiring directly into the Forward Interlock, Reverse Interlock, and All-Stop Interlock circuits.

Diving a little deeper into interlock signals:

  • Reverse Interlock – If a REV Interlock switch is activated, all the connected Stagehands will not allow further motion in the reverse direction until the interlock is cleared either by adjusting the switch mechanically or by moving in the forward direction far enough to clear the interlock switch. Traditionally, these switches are wired Normally Closed (N.C.) but can different depending on the application.

  • Forward Interlock – If any FWD Interlock switch is activated, the Stagehand will not allow further motion in the forward direction until the interlock is cleared either by adjusting the switch mechanically or by moving in the reverse direction far enough to clear the interlock switch. Traditionally, these switches are wired Normally Closed (N.C.) but can different depending on the application.

  • All-Stop Interlock – This circuit is used to halt motion in all directions as the name suggests. A dead man switch for operation or a pressure sensitive mat for a line-of-sight observer of the effect may be wired into this circuit. These switches would be wired Normally Closed (N.C.).

Safety Sensor Connections

The 4-Axis Safety Interlock supports 4 wire safety circuits (e.g. bumper switches, pressure mats). A 4 wire safety circuit, when used in conjunction with a safety relay, allows monitoring for the following four conditions:

  1. Disconnected – The safety relay sends out test pulses through the sensor and expects the signal to return. If that signal does not return the safety relay will go into a faulted state and disallow any further motion.

  2. Shorted – If a wire has been crushed by equipment or cut the safety relay will go into a faulted state.

  3. Cross Circuit – If the signals get crossed and the test pulse comes back on the opposite channel the safety relay will go into a faulted state.

  4. Good – If none of the above conditions occur the safety relay will not prohibit any movement.

The 4-Axis Safety Interlock comes with ML1 shorting plugs and XLR jumper cables. These should be installed on any interlocks or sensors that are not being used in your configuration. You can also temporarily override an interlock or sensor fault to move away from the obstruction that caused the fault.

When using the jumpers to override a fault, you will need to power cycle the 4-Axis Safety Interlock to clear the fault state.

Operation

Once powered up, the Safety Interlock is operational. If all of the connections have been properly made, the entire system is powered up, and none of the sensors or limit switches are activated, the Safety Interlock is actively doing its job. To verify this, the three indicator lights on the face should all be illuminated. Other than connecting or disconnecting any limit switches or sensors, there should be nothing else that needs to be done to the Safety Interlock itself.

Troubleshooting

When encountering an issue with the Safety Interlock Pro, the first thing to check would be that none of the limits or sensors are activated. If they are not, the next thing to check would be that all of the cables or jumpers are connected properly. If all connections are made properly and none of the sensors or limits are activated, it would be best to make sure that none of the cables have been cut or damaged.

Common Problems

The issue that is most often encountered is leaving an open connection. All connections on the back of the interlock need to have a physical cable or a jumper plugged in. Making sure that either the cables or the jumpers are seated properly is also important. It is common to mix up the sensor input and outputs in the forward and reverse direction.

Condition

Remedy

No indicator lights illuminated

Check main power

Only Power and REV safety sensor indicators illuminated

Confirm no FWD interlock is activated Confirm no FWD sensors activated Confirm bumpers/sensors are plugged into correct direction Terminate any unused FWD sensor output Power cycle the 4 Axis Interlock

Only Power and FWD safety sensor indicators illuminated

Confirm no REV interlock is activated Confirm no REV sensors are activated Confirm they are plugged into correct direction Terminate any unused FWD sensor output Power cycle the 4 Axis Interlock

Only Power indicator illuminated

Confirm no interlock is activated FWD and REV Confirm no sensor is activated FWD and REV Confirm they are plugged in to correct corresponding direction

Technical Support

  • Phone: 401-289-2942 x2

If you get stuck, we are here to help. The best way to get in touch with a tech expert is via email, even during normal business hours, because most days we are on the shop floor and may not be near the phone. There is someone in the office from 8:30a-5pm EST Monday-Friday, and they will return an email or phone call quickly. After hours, when most tech support issues arise, we have a crack team monitoring email and voicemail who will respond quickly to help get you moving.

ELECTRICAL SPECIFICATIONS

Power Input

Connector

  • Schurter 6200.2300

  • IEC-320 C-14

  • 3P 10A / 250VAC Male

Fuse

  • 5A / 250VAC

  • 10kA at 125VAC Interrupt Rating

  • 5mm x 20mm Medium-Acting

Tightening Torque

  • ¼” Quick Connect: Stake-On Crimped

  • Mounting Screw: 0.5Nm

Pinout

  • Pin L - L1 / 120VAC

  • Pin N - Neutral

  • Pin E - Ground

Low Voltage Fuse

Connector

  • Schurter 3101.0215

  • IP40 Fuse Holder

  • 10A / 250VAC

Fuse

  • 3.15A / 250VAC

  • 10KA at 125VAC Interrupt Rating

  • 5mm x 20mm Medium-Acting

Tightening Torque

  • ¼” Quick Connect: Stake-On Crimped

Interlock Input

Connector

  • Mencom CDM-08

  • 21mm x 21mm (3A)

  • 8P 10A Male

Tightening Torque

  • Pin 1 through 7 - HanD crimped

Pinout

  • Pin 1 - Forward/reverse interlock +24VDC source

  • Pin 2 - Forward interlock return

  • Pin 3 - Reverse interlock return

  • Pin 4 - All stop interlock +24VDC source

  • Pin 5 - All stop interlock return

  • Pin 6 - External fault +0VDC sink

  • Pin 7 - External fault signal

  • Pin 8 - Ground

Interlock Output

Connector

  • Mencom CDF-08

  • 21mm x 21mm (3A)

  • 8P 10A Female

Tightening Torque

  • Pin 1 through 7 - HanD crimped

Pinout

  • Pin 1 - Forward/reverse interlock +24VDC source

  • Pin 2 - Forward interlock return

  • Pin 3 - Reverse interlock return

  • Pin 4 - All stop interlock +24VDC source

  • Pin 5 - All stop interlock return

  • Pin 6 - External fault +0VDC sink

  • Pin 7 - External fault signal

  • Pin 8 - Ground

Forward Interlock Input

Electrical Spec

  • 24VDC

  • Normally closed circuit

Validation

  • When pin 2 is connected to the +24VDC source there is no forward interlock fault

  • When pin 2 is disconnected from the +24VDC source there is a forward interlock fault

While Running

  • When pin 2 is connected to the +24VDC source motion, happens

  • When pin 2 is disconnected from the +24VDC source, forward motion stops

  • When pin 2 is disconnected from the +24VDC source, motion can continue

Reverse Interlock Input

Electrical Spec

  • 24VDC

  • Normally closed circuit

Validation

  • When pin 3 is connected to the +24VDC source there is no reverse interlock fault

  • When pin 3 is disconnected from the +24VDC source there is a reverse interlock fault

While Running

  • When pin 3 is connected to the +24VDC source motion happens.

  • When pin 3 is disconnected from the +24VDC source reverse motion stops.

  • When pin 3 is disconnected from the +24VDC source forward motion can continue.

All Stop Interlock Input

Electrical Spec

  • 24VDC

  • Normally closed circuit

Validation

  • When pin 5 is connected to the +24VDC source there is no all stop interlock fault

  • When pin 5 is disconnected from the +24VDC source there is an all stop interlock fault

While Running (forward or reverse)

  • When pin 5 is connected to the +24VDC source motion happens.

  • When pin 5 is disconnected from the +24VDC source, all motion stops.

External Fault Input

Electrical Spec

  • 0VDC

  • Normally closed circuit

Validation

  • When pin 7 is connected to the +0VDC sink there is no all stop interlock fault.

  • When pin 7 is disconnected from the +0VDC sink there is an all external fault.

While Running

  • When pin 7 is connected to the +0VDC sink motion happens

  • When pin 7 is disconnected from the +0VDC sink motion stops

Reverse Interlock Input

Connector

  • Leviton ML1-R

  • 2P 15A Female

Tightening Torque

  • Pin 1 through 2 - 10-12 in-lbs

Pinout

  • Pin 1 - Reverse Interlock +24VDC source

  • Pin 2 - Reverse Interlock return

Electrical Spec

  • 24VDC

  • Normally closed circuit

Validation

  • When pin 2 is connected to the +24VDC source there is no reverse interlock fault.

  • When pin 2 is disconnected from the +24VDC source there is a reverse interlock fault.

While Running

  • When pin 2 is connected to the +24VDC source, motion happens.

  • When pin 2 is disconnected from the +24VDC source, reverse motion stops.

  • When pin 2 is disconnected from the +24VDC source, forward motion can happen.

Forward Interlock Input

Connector

  • Leviton ML1-R

  • 2P 15A Female

Tightening Torque

  • Pin 1 through 2 - 10-12 in-lbs

Pinout

  • Pin 1 - Forward interlock +24VDC source

  • Pin 2 - Forward interlock return

Electrical Spec

  • 24VDC

  • Normally closed circuit

Validation

  • When pin 2 is connected to the +24VDC source there is no forward interlock fault.

  • When pin 2 is disconnected from the +24VDC source there is a forward interlock fault.

While Running

  • When pin 2 is connected to the +24VDC source motion happens.

  • When pin 2 is disconnected from the +24VDC source forward motion stops.

  • When pin 2 is disconnected to the +24VDC source reverse motion can happen.

All Stop Interlock Input

Connector

  • Leviton ML1-R

  • 2P 15A Female

Tightening Torque

  • Pin 1 through 2 - 10-12 in-lbs

Pinout

  • Pin 1 - All Stop interlock +24VDC source

  • Pin 2 - All Stop interlock return

Electrical Spec

  • 24VDC

  • Normally closed circuit

Validation

  • When pin 2 is connected to the +24VDC source there is no all stop interlock fault.

  • When pin 2 is disconnected from the +24VDC source there is an all stop interlock fault.

While Running

  • When pin 2 is connected to the +24VDC source, motion happens.

  • When pin 2 is disconnected from the +24VDC source, forward and reverse motion stops.

Reverse Sensor Input

Connector

  • Neutrik NC3MD-L-1-BAG-1

  • 3 Pin XLR

  • 3P 16A Male

Tightening Torque

  • Pins 1 and 2 - Soldered

Pinout

  • Pin 1 - Channel 1 Input (+24VDC)

  • Pin 2 - Channel 2 Input (0VDC)

  • Pin 3 - Not used

Reverse Sensor Output

Connector

  • Neutrik NC3FD-L-1-BAG-1

  • 3 Pin XLR

  • 3P 16A Female

Tightening Torque

  • Pins 1 and 2 - Soldered

Pinout

  • Pin 1 - Channel 1 Output (+24VDC)

  • Pin 2 - Channel 2 Output (0VDC)

  • Pin 3 - Not used

Reverse Sensor Signal

Electrical Spec

  • 24VDC 5mA

  • Normally open circuit

Validation

  • When pin 1 on x6 has continuity to pin 1 on x7, AND pin 2 on x6 has continuity to pin 2 on x7, the REV Sensor Clear indicator on the front panel should be lit.

  • When pin 1 on x6 has no continuity to pin 1 on x7, OR pin 2 on x6 has no continuity to pin 2 on x7, the REV Sensor Clear indicator on the front panel should go out.

  • When pin 1 on x6 has continuity to pin 2 on x7, OR pin 2 on x6 has continuity to pin 1 on x7, the REV Sensor Clear indicator on the front panel should go out.

While Running

  • When pins 1 and 2 on X6 and are connected to pins 1 and 2 on X7 respectively, motion happens

  • When pins 1 and 2 on X6 are disconnected from pins 1 and 2 on X7 respectively, motion stops

  • When pins 1 and 2 on X6 are cross plugged to pins 1 and 2 on X7, motion stops. (can be tested with a short length of crush Bumper).

Forward Sensor Input

Connector

  • Neutrik NC3MD-L-1-BAG-1

  • 3 Pin XLR

  • 3P 16A Male

Tightening Torque

  • Pins 1 and 2 - Soldered

Pinout

  • Pin 1 - Channel 1 Output (+24VDC)

  • Pin 2 - Channel 2 Output (0VDC)

  • Pin 3 - Not used

Forward Sensor Output

Connector

  • Neutrik NC3FD-L-1-BAG-1

  • 3 Pin XLR

  • 3P 16A Female

Tightening Torque

  • Pins 1 and 2 - Soldered

Pinout

  • Pin 1 - Channel 1 Input (+24VDC)

  • Pin 2 - Channel 2 Input (0VDC)

  • Pin 3 - Not used

Forward Sensor Signal

Electrical Spec

  • 24VDC 5mA

  • Normally open circuit

Validation

  • When pin 1 on x8 has continuity to pin 1 on x9, AND pin 2 on x8 has continuity to pin 2 on x9, the FWD Sensor Clear indicator on the front panel should be lit.

  • When pin 1 on x8 has no continuity to pin 1 on x9, OR pin 2 on x8 has no continuity to pin 2 on x9, the FWD Sensor Clear indicator on the front panel should go out.

  • When pin 1 on x8 has continuity to pin 2 on x9, OR pin 2 on x8 has continuity to pin 1 on x9, the FWD Sensor Clear indicator on the front panel should go out.

While Running

  • When pins 1 and 2 on X6 and are connected to pins 1 and 2 on X7 respectively, motion happens

  • When pins 1 and 2 on X6 are disconnected from pins 1 and 2 on X7 respectively, motion stops

  • When pins 1 and 2 on X6 are cross plugged to pins 1 and 2 on X7, motion stops. (can be tested with a short length of crush Bumper).

Drawings

If you need any help along the way, contact us on our website (creativeconners.com), via email (), or by phone (401-289-2942).

Both forward and reverse motion will be interrupted unless pin #6 & pin #7 are connected on the Interlock Connector. This signal indicates that there is an electrical fault outside of the Stagehand preventing motion. The intention is to detect when a thermal overload relay has tripped on a single motor, when multiple motors are being powered by one Stagehand (e.g. a turntable being spun with multiple Machines).

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Safety Interlock - 4 Axis - Schematic Standalone.pdf
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4-Axis Front Panel
4-Axis Rear Panel