# Stagehand Pro 5: Sensor Input

![](https://3040525219-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2F-MhFI6SSKpm8M7EkrYqp%2Fuploads%2Fgit-blob-9b7debc9c7bf6c9a599533cd31e01cf0c74453f8%2Fsensor%20input.png?alt=media)

The 24-pin **Sensor Input** receptacle includes signal inputs for the following sensors:

* [Limit Switches](#limits) *(to prevent overtravel of a machine)*
  * [Ultimate](#ultimate-limits)
  * [Reverse](#reverse-limits)
  * [Forward](#forward-and)
* [Cross groove detection](#cross-groove-x-groove-detection) *(to halt a winch or hoist if cable is winding improperly)*
* [Load cell](#load-cell) *(to detect the weight being lifted by a machine)*
* [Encoder signals (x2)](#encoders)
  * [Speed monitoring](#speed-encoder)
  * [Positioning](#position-encoder)

## Limits

Limit signals are designed as fail-safe inputs. To allow movement in the corresponding direction, an electrical signal must be present. If the signal is interrupted, motion will stop. Limit switches should be wired **Normally-Closed (N.C.)** for failsafe operation.

| Pin # | Description           |
| :---: | --------------------- |
|   1   | +24VDC                |
|   2   | Ultimate Limit Signal |
|   3   | +24VDC                |
|   4   | Reverse Limit Signal  |
|   5   | +24VDC                |
|   6   | Forward Limit Signal  |

### Ultimate Limit

The Ultimate Limit signal is used as a redundant signal to halt motion if an initial **Forward** or **Reverse Limit** **Switch** failed to stop the machine. There is a single **Ultimate Limit Signal** on the Stagehand Pro 5. To protect both directions of travel, a pair of physical switches can be wired in series.

![Ultimate Limit Wiring](https://3040525219-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2F-MhFI6SSKpm8M7EkrYqp%2Fuploads%2Fgit-blob-358f1b7abebe71e7944476edcfb702710c8c074a%2FUlt%20Limits.png?alt=media)

{% hint style="warning" %}
Ultimate Limit switches should be physically positioned to trigger after the initial Forward and Reverse Limit switches.
{% endhint %}

If an Ultimate Limit is activated, the Stagehand will disallow any further movement in either direction until the limit is physically cleared or the **Ultimate Limit Override Button** is pressed. An **Ultimate Limit** activation indicates a failure of an initial limit switch and must be investigated. You cannot recover from an **Ultimate Limit** activation by running a cue.

### Reverse Limit

![Reverse Limit Wiring](https://3040525219-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2F-MhFI6SSKpm8M7EkrYqp%2Fuploads%2Fgit-blob-b933e2b7022a93b71e673f712d765042559fcf7c%2Fsensor%20rev%20limit.png?alt=media)

A **Normally-Closed (N.C.)** switch can be wired into the **Reverse Limit** input. If the limit switch is activated, the Stagehand will not allow further motion in the reverse direction until the limit is cleared by any of the following means:

* moving in the forward direction far enough to clear the limit switch
* adjusting the switch mechanically
* pressing the **Reverse** **Limit Override Button** if it is safe to do so

### Forward Limit

![Forward Limit Wiring](https://3040525219-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2F-MhFI6SSKpm8M7EkrYqp%2Fuploads%2Fgit-blob-e15e01b03f1312ce619bfef4bf82ee9380ded26b%2Fsensor%20fwd%20limit.png?alt=media)

A **Normally-Closed (N.C.)** switch can be wired into the **Forward Limit** input. If the limit switch is activated, the Stagehand will not allow further motion in the forward direction until the limit is cleared by any of the following means:

* moving in the reverse direction far enough to clear the limit switch
* adjusting the switch mechanically
* pressing the **Forward** **Limit Override Button** if it is safe to do so.

### Common Wiring - Alternate

{% hint style="info" %}
Each signal pair has a voltage source pin and a signal pin. The voltage sourcing pins (indicated as +24V on the diagram above) are all equivalent and are distributed for convenience. They can be wired in pairs, or a single source pin can be used to reduce conductor count.
{% endhint %}

![Alternate Wiring To Reduce Conductor Count](https://3040525219-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2F-MhFI6SSKpm8M7EkrYqp%2Fuploads%2Fgit-blob-b7bcccdff103e04816d60340232f2168753a00bb%2Fsensor%20common%20wiring.png?alt=media)

## Cross Groove(X-Groove) Detection

![X-Groove Detection Sensor Wiring](https://3040525219-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2F-MhFI6SSKpm8M7EkrYqp%2Fuploads%2Fgit-blob-e71e0823c13873c4634ac556da486940ce7cad4e%2Fx-groove.png?alt=media)

| Pin # | Description        |
| :---: | ------------------ |
|   1   | 24VDC              |
|   3   | 24VDC              |
|   5   | 24VDC              |
|   9   | Cross Groove Input |
|   11  | 24VDC              |

The **Cross Groove (X-Groove) Detection** will halt all motion unless +24VDC is supplied to **input pin #9**. Most commonly, this signal is used on a winch or hoist to stop motion when the wire rope jumps a groove because of pulley misalignment.

To clear the **Cross Groove Fault**, press the **Sensor Override Button** and jog the machine in the opposite direction until there is no longer a cross groove.

{% hint style="warning" %}
Not every machine needs Cross Groove Detection. If your machine does not utilize **Cross Groove Detection**, you must jump **input #9** with a +**24VDC source pin** to enable motion.
{% endhint %}

{% hint style="info" %}
The **Cross-Groove Detection** signal does not have a dedicated voltage source pin. Instead, source the signal voltage from any of the +24VDC pins listed in the table above.
{% endhint %}

## Load Cell

| PIn # | Description                              |
| :---: | ---------------------------------------- |
|   10  | Load Cell Signal - Analog Input (4-20mA) |
|   11  | +24VDC                                   |
|   12  | COM (0VDC)                               |

The **Load Cell Input** is an analog signal to read the weight being lifted, or force exerted, by a machine. The load cell can be powered by **Pins #11 & #12**. **Pin #10** will read a 4-20mA analog signal from the load cell. The 4-20mA signal can be scaled in Spikemark to display accurate load readings.

In addition to displaying the load, the Stagehand can be configured to halt when either the load exceeds a maximum value (**Overweight Fault**) or drops below a minimum value (**Underweight Fault**).

To clear a **Load Cell Fault** either:

* Reduce the load (overweight)
* Clear the obstruction (underweight)
* Push the Sensor Override button and manually jog the motor

{% hint style="info" %}
**Underweight** and **Overweight** **Alarms** can be disabled through Spikemark.
{% endhint %}

## Encoders

| Pin # | Description           |
| :---: | --------------------- |
|   13  | Speed Encoder - A     |
|   14  | Speed Encoder - /A    |
|   15  | Speed Encoder - B     |
|   16  | Speed Encoder - /B    |
|   17  | +5VDC                 |
|   18  | COM (0VDC)            |
|   19  | Position Encoder - A  |
|   20  | Position Encoder - /A |
|   21  | Position Encoder - B  |
|   22  | Position Encoder - /B |
|   23  | +5VDC                 |
|   24  | COM (0VDC)            |
|  GND  | Shield                |

Stagehand Pro 5 utilizes two encoder signals. One for monitoring speed and one for positioning.

Encoder requirements:

* 5 VDC
* Incremental quadrature encoder signal
* Differential line drivers: A, /A, B, /B

{% hint style="info" %}
Z and /Z index pulses are not used, but encoders with those signals are compatible with the Stagehand Pro 5.
{% endhint %}

{% hint style="info" %}
Both encoder signals *can* come from a single encoder by splitting the signal to both inputs.
{% endhint %}

### Speed Encoder

The **Speed Encoder** should be directly connected to the motor. It provides feedback to the Variable Frequency Drive (VFD) to monitor overspeed faults. It also provides precise speed regulation which enables full-torque at zero-speed. This signal is used by the VFD to verify the speed of the machine closely matches the commanded speed whether running cues, or jogging manually.

{% hint style="warning" %}
The speed encoder signal is used solely by the VFD for closed-loop vector speed control. If the VFD is switched to a sensorless speed control mode, the speed encoder signal is not used.
{% endhint %}

### Position Encoder

The **Position Encoder** provides feedback to the Stagehand Card to track the position of the machine or scenery. It is actively used to run cues, and it is constantly monitored to track the position of the machinery or scenery at all times. However, it is not actively used during manual operation (aka jogging). This allows for manual operation in case of a position encoder failure.

{% hint style="info" %}
Position information is stored in the Stagehand's memory so it remembers the location of the machine during a loss of power. We call this **Persistent Position**. The Persistent Position data is written to the Stagehand Pro every 500ms.
{% endhint %}