Stagehand 4: Machine Configuration
The Stagehand Pro 4 is really two devices in one package:
Variable Frequency Drive (VFD) – the power source for the motor that can spin the motor at (nearly) any speed with exceedingly accurate speed control.
Motion controller (aka the Stagehand Card) – a small computer that signals to the VFD when to start, what speed to move, and when to stop. It uses the Sensor Inputs to keep track of the position of the scenery and run cues.
The VFD must be configured to match the motor it spins. Without proper VFD configuration, the motor will either not move at all, or won't move smoothly. The motion controller is not used during manual operation (jogging), it is only used to run cues with Spikemark. But the VFD is used any time the motor spins. Even for the simplest operation, the VFD must be properly configured for the machine it powers, so it's important to get it set up correctly first.
Out of the box, the Stagehand Pro 4 is configured to power a 5HP machine like our Pushstick, Revolver, or Spotline. If you're using one of those machines, you can skip to Manual Operation.
VFD Presets
The Mitsubishi A800 VFD inside the Stagehand Pro 4 has hundreds of parameters that can be configured to alter the behavior of the drive. We preset all the parameters for general purpose use, but you may need to change a parameter for the drive to work properly with a specific machine. Or you may suspect that a parameter is incorrectly set and would like to verify the current value of that parameter. There are two methods for setting parameters: use the keypad, or restore from internal USB storage.
Restore from USB
Inside the Stagehand Pro 4, we have installed a USB flash drive into the VFD. The flash drive contains sets of parameters for our stock machinery that were current at the time the Stagehand Pro 4 in your hands now was made.
There are three standard parameter files stored in the VFD as a backup in case a parameter change renders the drive inoperable. These files are stored as follows:
CP001 - Standard 5HP Settings (Pushstick, Revolver & Spotline)
CP002 - Floorpocket Settings
CP003 - CM Smart Chain Hoist Settings
To restore one of the saved parameter files:
Press MODE 4X (Displays USB-A)
Press SET 3X (Displays CP---)
Scroll to desired program number (ie CP001)
Press SET 1X (Displays 0.---)
Scroll two clicks right (Displays 2.WR)
Press SET 2X (Displays Flashing 2.ALL)
The VFD will think for a while as it copies all the parameters from the USB drive. When it’s finished, it will beep. After the beep, reset the drive by cycling the main power breaker.
Saving to USB
Saving a new parameter set to the internal USB storage is an advanced topic that could overwrite our factory-default parameter sets and cause the Stagehand to stop functioning. You’ve been warned. Proceed with caution.
If you have a set of parameters for a machine of your own making, or made tweaks to the stock parameters that you’d like to save, you can save your new parameter set to the USB storage device inside the Stagehand Pro 3. There are 99 available slots that can be saved. We recommend that you start with slot CP004 and work your way up rather than overwrite the standard settings. To save your parameters to a new file on the USB storage:
Press MODE 4X (Displays USB-A)
Press SET 3X (Displays CP---)
To overwrite an existing file skip to step to Step 3
To save a new file location press SET 1X (Displays 0.---)
Scroll one click to the right (Displays 1.RD)
Go to step 6
Scroll to desired program number. (ie CP004)
Press SET 1X (Displays 0.---)
Scroll Right one click (Displays (1.RD)
Press SET 1X
The VFD will think for a while as it copies all the parameters onto the USB drive. When it’s finished, it will beep. After the beep, reset the drive by cycling the main power breaker.
Parameter Configuration
Using the VFD Keypad
Using the keypad to set parameters works well for changing a small number of parameters. It’s also a handy way to quickly verify the value of a parameter. To view a parameter:
Press the MODE button on the keypad until the display reads “P. 0” (it may be a different number, the important part is P.).
Now you can scroll through all the parameters with the wheel on the keypad.
Press the SET button when you reach the desired parameter.
The current value of the parameter is displayed.
You can:
Change the value with the scroll wheel and press SET to save
Without changing the value, press SET to return to the parameter list
Return to the parameter list discarding changes by pressing ESC
VFD Configuration with Spikemark
You can use Spikemark to adjust parameters on the VFD.
Analog Speed Calibration
Your Stagehand uses an analog input signal to communicate to the VFD how fast and in which direction to turn. In order to ensure your machine moves as fast as physically possible, the VFD should be calibrated to the Stagehand motion controller so that a 100% control signal results in a 60Hz output frequency to the motor. Some models have their factory calibration printed on a label on the back showing the value that should be entered in Parameter C4. If your Stagehand does not have C4 parameter sticker on the back, you can follow this procedure to calibrate the analog speed signal. Note that your stagehand needs to be connected to a motor that can be safely run at full speed (preferably not attached to scenery).
On the Mitsubishi keypad press MODE until the display reads P.0
Rotate the dial until you get to C…
Press SET
Rotate the dial to C4
Press SET
Jog forward to 100%
While jogging press SET on the VFD keypad to record the analog input gain. The display on the VFD will flash between your new number and P C4
Stop jogging the motor
Factory Defaults
There are times when you find yourself in the weeds with a misbehaving Stagehand and nothing you do seems to make a difference. For me these times generally coincide with changing parameters, running an auto-tune or (of course) 1st tech/1st dress/1st preview. VFDs are complicated devices, one wrong parameter can wreak havoc - tossing out errors, not triggering the brakes or just not working at all. Let's take a look at what to do when it's time to reset the VFD to factory defaults.
In our shop we are able to execute a "mind wipe" from the bench computer. Without this tool in hand, your only sane option is to execute a parameter clear from the keypad. This may sound like a scary prospect, but quite often it is the quickest and simplest approach to get back on track. In order to restore factory defaults we need to execute two different CLEAR functions, an ALL CLEAR and a PARAMETER CLEAR. You may be asking yourself why the all clear doesn’t actually clear ALL items… it is because these two functions clear different sections of the memory.
Press mode until the display shows P.0
Set Pr. 77 to 0
Set Pr. 79 to 1 (this unlocks PU mode)
Set Pr. 551 to 9999
Cycle power to the drive
Press mode until the display shows P.0
Scroll to ALL.CL and set to 1 (the display will flash between ALL.CL and 1 once set)
Scroll to PR.CL and set to 1 (the display will flash between PRCL and 1 once set)
Power cycle the VFD
Now the VFD is in the default state from the factory. Before you can use it again, you must reload one of our parameter sets onto the VFD. Use either the Keypad or USB Storage techniques outlined above to load a parameter set that matches your machine.
The parameter sets for our stock machines are shown in attached PDF below Some of the parameters listed are unchanged from the Mitsubishi default, but it’s good to verify all of them are correct.
VFD Auto-Tuning
The Mitsubishi A800 has a built-in “auto-tuning” procedure which electrically probes the motor to give the VFD a better understanding of the motor it is tasked with controlling. Auto-tuning should be run every time you connect the Stagehand to a different motor.
You should also run auto-tuning any time that you change cable lengths between the Stagehand and the machine.
The operation typically takes less than a minute and does not move the motor shaft substantially but will release the motor brake so the drive can sense the motor’s reaction to applied power.
There are two methods available to execute the Auto-Tuning procedure:
Using the VFD Keypad
From within Spikemark
The Stagehand Pro uses the Mitsubishi’s internal PLC to insure safe operation of the redundant brake circuits. This PLC feature must be turned off in order run the “auto-tuning” procedure. This procedure is automated from within Spikemark with a click of the mouse. You will need to stop the PLC program manually If running the auto-tune procedure from the VFD keypad.
Using the VFD Keypad
Turn off PLC mode governing the Brake Test circuitry using the VFD keypad
Enter the Parameter Setting mode by pressing the MODE button on the VFD keypad until the display reads P. 0
Scroll the wheel to find parameter P 414.
Press the SET button to adjust the parameter.
Scroll down to the value 0 to turn off the PLC program.
Press the SET button to accept the new value.
Restart the VFD by either cycling power to the Stagehand, or by pressing the Emergency Stop button on the Showstopper and release it. Activating the Emergency Stop circuit will remove power from the VFD.
Set key parameters on the VFD keypad
Set Parameter 9 equal to the rated current of the motor. (14A for 5hp)
Set Parameter 71 equal to 3. This is the setting for a general purpose motor.
Set Parameter 81 equal to the number of motor poles appropriate for the base rpm of the motor (2 for 3600 rpm, 4 for 1800 rpm, 6 for 1200 rpm). (4-pole motors are most common)
Set Parameter 83 equal to the rated voltage of the motor. (230V is standard)
Start the Auto-Tune sequence
Set Parameter 96 equal to 1. This will execute auto-tuning without moving the motor.
Press the MODE button until the keypad displays a 1 without flashing. You will need to press the mode button thrice.
Press and hold the Brake Test button.
While holding the Brake Test button, press and hold the Forward button on the Stagehand motion controller (not the VFD keypad).
You must press both buttons for about a minute while the VFD performs the auto-tuning procedure. The keypad will display 2 while running the tuning procedure. The motor will make some very odd noises during auto-tuning, it sounds like the motor is chirping in various rhythms. This is normal.
If the auto-tuning completes successfully, the VFD keypad will display 3. If there was an error another number will be shown. Consult the Mitsubishi A800 manual for more details on the error. The explanation can be found starting on page 433.
Restart the PLC program in the VFD:
Enter the Parameter Setting mode by pressing the MODE button on the VFD keypad until the display reads P.XXX (where XXX is any number from 0 – 999).
Scroll the wheel to find parameter P.414.
Press the SET button to adjust the parameter.
Scroll down to the value 2 to turn on the PLC program.
Press the SET button to accept the new value.
Restart the VFD by either cycling power to the Stagehand, or by pressing the Emergency Stop button on the Showstopper and release it. Activating the Emergency Stop circuit will remove power from the VFD.
After the VFD turns on, confirm the P.RUN light on the VFD keypad is illuminated and not flashing. This indicates that the brake logic is functioning correctly.
Auto-tuning with Spikemark
You can perform VFD auto-tuning through Spikemark with less fuss.
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