Safety Interlock Pro 4
Reference Manual v1.0
Last updated
Reference Manual v1.0
Last updated
The Safety Interlock Control 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.
The Safety Interlock Control - Pro 4 is designed to integrate perfectly with your Stagehand Pro 4 through the Interlock Input. The Safety Interlock also has a pass-thru connection, so you can use it by with the just the Stagehand Pro 4 and wire your safety switches directly to this input, or daisy chain multiple Safety Interlocks together
This manual will guide you through:
Unpacking
Installation
Powering up
Operation
Troubleshooting
If you need any help along the way, contact us on our website (creativeconners.com), via email (support@creativeconners.com), or by phone (401-289-2942 ext 2).
In the box you will find:
Safety Interlock Pro 4
Two 3-pin XLR jumpers
Three interlock jumpers (same ML-1 connector as limit jumpers)
If any of these parts are missing, please contact us.
If you ordered any bumper switches or pressure mats those items are packaged separately.
The Safety Interlock Pro is a 2U rack mountable device with 4 mounting holes. Listed below are additional features of the Interlock:
Three indicator lights to show the status of the Safety Interlock
Interlock input from the Stagehand Pro 4
Interlock output to the machine
Discreet interlock sockets
Forward and reverse 4-wire sensor inputs (one input and output for each direction)
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!
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.
There are four basic connections that you need to be concerned with on the Safety Interlock Pro 4:
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.
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.
The Interlock Terminator ships with the Stagehand Pro 4 and should be plugged into the Interlock Output whenever the Interlock Inputs are not being used. It can also be installed temporarily to defeat an Interlock Fault to drive the machine clear of an obstruction, provided it is safe to do so.
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 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.
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.
A pushbutton can be wired into the All-Stop Interlock as an enable button for a lift. Unless the button is depressed, no movement is allowed.
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 Revolver machines).
The Stagehand Pro 4 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.).
The Safety Interlock adds additional support for 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:
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.
Shorted - if a wire has been crushed by equipment or cut the safety relay will go into a faulted state.
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.
Good - if none of the above conditions occur the safety relay will not prohibit any movement.
If you are using tape switches (safety bumpers) or safety mats, they will plug into one of these two circuits. The Reverse Sensor, when triggered by any of the above conditions, will cause a Reverse Interlock error on the Stagehand. The Forward Sensor when triggered, will cause a Forward Interlock error on the Stagehand.
The 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 Safety Interlock to clear the fault state.
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.
When encountering an issue with the Safety Interlock, 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.
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 and connection from Stagehand Pro 4
Only Power and REV safety sensor indicators illuminated
Confirm no FWD interlock is activated
Confirm no FWD sensors activated
Confirm they are plugged into correct direction
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
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
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.
Online: www.creativeconners.com
Email: support@creativeconners.com
Phone: 401-289-2942 x2
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
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
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
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.
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.
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
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.
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.
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.
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
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
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).
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
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
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).
