Docs
Download Spikemark
  • Creative Conners Docs
  • Technical Support
    • Tech Tips
      • Revolver V1 Position Issues
      • Setting Up a New Comptuer for Spikemark
  • Spikemark 6
    • Navigating Spikemark
      • Show Modes
      • Workspaces
        • Jog Workspace
        • Cues Workspace
        • Preset Workspace
        • Customize Your Workspace
      • Selection and Input
      • Tags
      • Filters
      • Search
      • Keyboard Shortcuts
    • Cues
      • Cue Structure
      • Cue Creation
        • Add Movements
        • Add Triggers
        • Add Actions
      • Editing Cue Properties
      • Cue Deletion
    • Movements
      • Motor Movements
      • Locked Group Movements
      • Unlocked Group Movements
      • FX Movements
      • OSC Movements
        • Custom OSC Command Library
      • UDP Movements
      • Modbus Movements
    • Triggers
      • Playback Go Trigger
      • Delay Trigger
      • Completion Trigger
      • Position Trigger
      • FX Input Trigger
      • Stacking Triggers
    • Actions
      • Motor Property Action
      • Motor Method Action
      • Playback Property Action
    • Running Cues
      • Playbacks
        • Playback Editing
        • Playback Control Speed
        • Playback Stacking
      • Cue Controls
      • Console
      • Consolette
      • Restore Cue
    • Spikes
      • Simple Spikes
      • Dynamic Spikes
        • Incremental Spikes
        • Nearest Forward Multiple Spikes
        • Nearest Reverse Multiple Spikes
        • Nearest Multiple Spikes
      • Locked Group Spikes
    • Presets
      • Presets Overview
      • Creating, Editing, and Deleting Presets
      • Running Presets
    • User Authentication and Authorization
      • Overview
      • Users
      • Roles
      • Permissions
    • Show Control
      • Open Sound Control (OSC)
        • Send OSC Messages
        • OSC Position Output
        • OSC Input Trigger
          • OSC Input Messages
          • Cue Messages
          • Playback Messages
          • Sequence Step Messages
          • Motor Movement Messages
          • Motor Messages
        • Troubleshooting OSC
          • OSC Response Window
          • Medialon Manager Configuration
      • UDP
        • Send UDP Messages
        • UDP Position Output
      • Watchout Position Output
      • PosiStageNet (PSN)
  • Spikemark 5
    • How to Open Spikemark
    • Spikemark Installation
      • User Authorization
      • Windows Settings
    • Quick Start Tutorial
      • Step 1: Adding Motors
        • 1.1 Simulator Mode
        • 1.2 Add Motors from the Machine Library
        • 1.3 Rename Motors
        • 1.4 Add A Group
      • Step 2: Saving
      • Step 3: Jogging
        • 3.1 Single Axis Jogging
        • 3.2 Jogging Multiple Machines (Multi-Jog)
        • 3.3 Move To Position
      • Step 4: Writing Your First Cues
        • 4.1 Cues Workspace
        • 4.2 Add A Movement
        • 4.3 Duplicate A Cue
        • 4.4 Delete A Movement From A Cue
        • 4.5 Edit Movement - Changing Position, Speed, and Time
        • 4.6 Copy to Group
        • 4.7 Cue Total Time
        • 4.8 Load and Run your Cue
        • 4.9 Spikes
        • 4.10 Cue Links
        • 4.11 Restore Cue
        • 4.12 Delete A Cue
      • Step 5: Going Live
        • 5.1 Set Your IP Address
        • 5.2 Test Manual Movement
        • 5.3 Resetting Position
        • 5.4 Program Your Show
      • Sharpen Your Programming Skills
    • Steps to a Successful Load-In
    • Show Modes
    • Locking Changes
    • Workspaces
      • Customize Your Workspace
    • Selection and Input
    • IP Address and Network Connection
      • Setting Computer IP Address
      • Setting Stagehand IP Address
      • Setting Showstopper Consolette IP Address
      • Setting Pendant IP Address
      • Setting Showstopper IP Address
      • Setting Showstopper Node ID
      • Connecting To A Stagehand
      • Connecting To A Showstopper Consolette
      • Connecting To A Pendant
    • Adding Motors or Machines
      • Adding Motors or Machines From The Machine Library
      • Adding Custom Motors or Machines To Spikemark
      • Importing Motors or Machines
      • Exporting Motors or Machines
    • Stage Model Viewer
      • Changing Your Viewer
      • Adjusting the Stage Size
      • Changing the Type of Scenery
      • Adjusting Model Dimensions
      • Adjusting Model Rotation
      • Adjusting Location On Stage
      • Making Models
        • Modeling A Winch
        • Modeling A Lift
        • Modeling A Hoist
        • Modeling A Vertical Curtain
        • Modeling A Split Curtain
        • Modeling A Turntable or Periaktos
    • Tags
    • Editing Direction Labels
    • Filters
    • Search
    • Position
      • Reset Position
      • Units
      • Position Scale
        • Position Scale Wizard
        • Manually Calculate Position Scale
      • Limits
        • Setting Hard Limits
        • Setting Soft Limits
      • Target Tolerance
      • Strict Timing Mode
      • Position Fault and Max Position Error
      • Motor Tuning Overview
        • Motor Tuning - The Practical Approach
    • Load Cell
      • Load Cell Readout
      • Load Cell Configuration
      • Load Cells and Groups
    • Speed
    • Spikes
      • Adding A Spike
      • Removing A Spike
      • Spike Input Fields
      • Simple Spike
      • Incremental Spike
      • Nearest Forward Multiple Spike
      • Nearest Reverse Multiple Spike
      • Nearest Multiple Spike
    • Editing Cues
      • Adding and Deleting Cues
      • Adding and Deleting Movements
      • Edit Movement
      • Edit Cue Options
    • Cue Controls
    • Cue Status
    • Cue Links
      • Completion Link
      • Time Link
      • Position Link
      • Input Link
      • Deleting A Cue Link
    • Presets
    • Motor Groups
    • Showstopper Node Editor
    • Show Control
      • Open Sound Control (OSC)
        • OSC Position Output
        • OSC Messenger
          • Expanding The Command Library
        • OSC Response Window
        • OSC Input Trigger
          • Input Messages
          • Cue Commands
          • Motor Commands
          • My OSC Input Trigger Isn't Working, Is there another way?
      • UDP
        • UDP Position Output
        • UDP Messenger
      • Watchout Position Output
      • Modbus Effect
      • PosiStageNet (PSN)
    • Drive Communication
      • Drive Information
      • Configuring The Drive
      • Analyzing Movements
      • Drive Communication: Compatibility
      • Drive Communication: Setting VFD Parameters
      • RS-485 Upgrade
        • Upgrading an A800
        • Upgrading an A700
        • Drive Communication Troubleshooting
      • VFD Fault Codes
    • Motor Status Icons
    • Keyboard Shortcuts
    • Advanced Cue Techniques
  • Showstopper
    • Showstopper 4 Base
      • Installation
      • Operation
      • Troubleshooting
      • Specifications
    • Spikemark Console
      • Making-The-Connections
      • Using-the-Console
      • Console-Firmware
      • Troubleshooting
      • Specifications
    • Spikemark Pendant V2
      • Getting Started
      • Setup
      • Operation
      • Troubleshooting
      • Specifications
      • Drawings
    • Showstopper 4 E-Stop Hub
      • Getting Started
      • Installation
      • Operation
      • Troubleshooting
      • Specifications
    • Showstopper 4 Accessory Hub
      • Getting Started
      • Installation
      • Operation
      • Troubleshooting
      • Specifications
    • Showstopper Remote E-Stop
      • Installation
      • Making The Connections
      • Operation
      • Troubleshooting
      • Specifications
    • Control Connection
      • Installation
      • Making The connections
      • Operation
      • Troubleshooting
      • Specifications
    • Drive Connection
      • Installation
      • Making The connections
      • Operation
      • Troubleshooting
      • Specifications
    • Showstopper E-Stop Patch Panel
    • Showstopper Accessory Patch Panel
    • 🦺Safety Interlock
      • Safety Interlock Classic
      • Safety Interlock Pro
      • Safety Interlock Pro 4
      • 4-Axis Safety Interlock
    • Legacy
      • Showstopper 3 Base
      • Showstopper 3 Remote
      • Showstopper 3 E-Stop Patch Panel
      • Stage Manager
        • Getting Started
        • Installation
        • Making the Connections
        • Operation
        • Troubleshooting
        • Specifications
      • Showstopper 4 Consolette
        • Features
        • Making the Connections
          • Accessory Cable Connection
          • Ethernet Connection
          • Multiple Consolettes
        • On-Board Settings
        • Operation & Spikemark Integration
        • Connecting the Consolette to Spikemark
        • Jogging Motors
        • Running Cues
        • Emergency Stop
        • Updating Consolette Firmware
        • Troubleshooting
        • Physical Specifications
        • Drawings
  • Stagehand
    • Stagehand Firmware
      • Manually Updating a Stagehand Unipolar V6 Card via SD Card
      • Manually Updating a Stagehand Unipolar V6 Card via USB
    • Stagehand Parameters
      • Stagehand Pro 2 Parameters
      • Stagehand Pro 3/Pro 4 Parameters
      • Stagehand Pro 3e Parameters
      • Stagehand Pro 5 Parameters
      • Stagehand Apprentice 2 Parameters
      • Stagehand Apprentice
      • Stagehand AC - AKA: The Classic
      • Classic+ Parameters
      • Pro+ Parameters
      • Setting the C3 Value
      • Setting the C4 Value
      • All Clear/Parameter Clear
      • How to Use the Mitsubishi VFD Keypad
      • USB Parameter Sets
      • Parameter Library in Spikemark
    • Stagehand Apprentice
      • Getting Started
      • Installing the Stagehand
      • Making the Connections
      • Hooking up a motorized effect
      • Using the Stagehand
      • Troubleshooting
      • Technical Support
      • Specifications
    • Stagehand Apprentice DC
    • Stagehand Apprentice 2
      • Stagehand Apprentice 2: Features
      • Stagehand Apprentice 2: Installation
      • Stagehand Apprentice 2: Making The Connections
        • Stagehand Apprentice 2: Power Input
        • Stagehand Apprentice 2: Motor and Brake Output
        • Stagehand Apprentice 2: Sensor Input
        • Stagehand Apprentice 2: Interlock Inputs
        • Stagehand Apprentice 2: Ethernet Input
        • Stagehand Apprentice 2: Showstopper Emergency Stop Input
      • Stagehand Apprentice 2: Operation
      • Stagehand Apprentice 2: Troubleshooting
      • Stagehand Apprentice 2 Specifications
      • Stagehand Apprentice 2: Drawings
    • Stagehand FX
      • Getting Started
      • Making the Connections
      • Connecting an Effect
      • Operation
      • Troubleshooting
      • Specifications
    • Stagehand Hydraulic
      • Getting Started
      • Features
      • Installation
      • Operation
      • Troubleshooting
      • Technical Support
      • Specifications
      • Drawings
    • Stagehand Pro 3
    • Stagehand Pro 3E
    • Stagehand Pro 4
      • Stagehand Pro 4: Unpacking
      • Stagehand Pro 4: Installation
      • Stagehand Pro 4: Making The Connections
        • Stagehand Pro 4: Power Input
        • Stagehand Pro 4: Motor and Brake Output
        • Stagehand Pro 4: Sensor Input
        • Stagehand Pro 4: Interlock Inputs
        • Stagehand Pro 4: Ethernet Input
        • Stagehand Pro 4: Showstopper Emergency Stop Input
      • Stagehand Pro 4: Operation
        • Stagehand Pro 4: Powering Up
        • Stagehand 4: Machine Configuration
        • Stagehand Pro 4: Manual Operation (Jogging)
        • Stagehand Pro 4: Brake Test
        • Stagehand Pro 4: Connecting to Spikemark
        • Stagehand Pro 4: Status Displays
      • Stagehand Pro 4: Troubleshooting
        • Stagehand Pro 4: Recovering From Faults
        • Stagehand Pro 4: Monitoring Behavior
      • Stagehand Pro 4: Specifications
      • Stagehand Pro 4: Drawings
    • Stagehand Pro 5
      • Stagehand Pro 5: Features
      • Stagehand Pro 5: Installation
      • Stagehand Pro 5: Making The Connections
        • Stagehand Pro 5: Power Input
        • Stagehand Pro 5: Motor and Brake Output
        • Stagehand Pro 5: Sensor Input
        • Stagehand Pro 5: Interlock Inputs
        • Stagehand Pro 5: Ethernet Input
        • Stagehand Pro 5: Showstopper Emergency Stop Input
      • Stagehand Pro 5: Operation
      • Stagehand Pro 5: Troubleshooting
      • Stagehand Pro 5 Specifications
      • Stagehand Pro 5: Drawings
      • Stagehand Pro 5: Replace Control Card
    • Deck Chief 2
      • Getting Started
      • Features
      • Making the Connections
      • Using the Deck Chief
      • Troubleshooting
      • Specifications
    • Stagehand Classic+
    • Stagehand Pro+
    • Legacy Manuals
      • Deck Chief
        • Getting Started
        • Installation
        • Making the Connections
        • Using the Deck Chief
        • Troubleshooting
        • Specifications
        • Deck Chief Legacy Connections
      • Stagehand Mini^2
      • Stagehand Pro AC (Pro 2)
      • Stagehand AC
      • Stagehand Mini
      • Stagehand DC & DC Max
    • X-Groove Override
  • Machinery
    • Smart Chain Hoist
      • Getting Started
      • Installation
      • Making the Connections
      • Under The Hood
      • Troubleshooting
      • Specifications
    • Floorpocket
      • GettingStarted
      • Installation
      • Making the Connections
      • Prepping the Machine for Operation
      • VFD Settings
      • Troubleshooting
      • Specifications
    • Floorpocket v2
      • Get Started
        • Unpack
        • Installation Tools
      • Assembly
        • Base
        • Column Extension
        • Limit Cables
        • Roller Chain
      • Get Moving
        • Power Up
        • Platform
        • Stay Safe
        • Write Cues
      • Maintain the Machine
      • Troubleshooting
      • Floorpocket v2: Specifications
    • Pivot
      • Getting Started
      • Installation
      • Troubleshooting
      • Specifications
    • Pushstick
      • Getting Started
      • Installation
      • Making the Connections
      • Rigging the Pushstick
        • Rigging a Pushstick v2
      • Setting the Limits
      • Troubleshooting
      • Specifications
    • Pushstick Mini
      • Getting Started
      • Installation
      • Making the Connections
      • Rigging the Pushstick Mini
      • Troubleshooting
      • Technical Support
      • Specifications
    • Revolver
      • Installation
      • Making the Connections
      • Making It Move
        • Friction Wheel Tension Guide
      • Position Scaling
        • Encoder Finessing
      • Troubleshooting
      • Specifications
        • Drawing
      • Multi-Motor Configuration
      • Revolver v1 Manual
    • Rotator
      • Getting Started
      • Installation
      • Making the Connections
      • Troubleshooting
      • Technical Support
      • Specifications
    • Spotline
      • Getting Started
      • Installation
      • Rigging the Spotline
      • Operation
      • Troubleshooting
      • Specifications
    • Spotline V2
      • Spotline V2: Setup Process
      • Spotline V2: Installation
      • Spotline V2: Rigging the Spotline
      • Spotline V2: Operation
      • Spotline V2: Troubleshooting
      • Spotline V2 Accessories
      • Spotline V2: Maintenance
      • Spotline V2: Specifications
    • Spotline Mini v2
    • Spotline Practical
      • Practical v2
        • Getting Started
        • Installation
        • Rigging the Machine
        • Setting the Limits
        • Troubleshooting
        • Specifications
      • Practical v1
        • Getting Started
        • Installation
        • Operation
        • Troubleshooting
        • Specifications
    • Turntable Template
      • Overview
      • Bill Of Materials
      • Fabrication
      • Turntable Assembly and Installation
      • Turntable Assembly Guide
      • Tech Support
      • 20' Turntable Specs
      • Turtable Research Notes for Nerds
    • Retired
      • Curtain Call
      • Trickline
        • TricklineProductManualv1.0
        • Getting Started
        • Installation
        • Making the Connections
        • Troubleshooting
        • Specifications
      • Spotline Mini
        • Getting Started
        • Installation
        • Making the Connections
        • Rigging the Spotline Mini
        • Troubleshooting
        • Specifications
      • Pushstick Manual
    • Stromag Limits
  • Broadweigh Load Cells
Powered by GitBook
On this page
  • Emergency Stop Fault
  • Limit Faults
  • Reverse Limit
  • Forward Limit
  • Ultimate Limit
  • Further steps
  • Drive Faults
  • Brake Fault
  • Cross-Groove Fault
  • Load Cell Faults
  • Interlock Faults

Was this helpful?

  1. Stagehand
  2. Stagehand Pro 4
  3. Stagehand Pro 4: Troubleshooting

Stagehand Pro 4: Recovering From Faults

PreviousStagehand Pro 4: TroubleshootingNextStagehand Pro 4: Monitoring Behavior

Last updated 2 years ago

Was this helpful?

Emergency Stop Fault

Inside the Stagehand Pro 4, a safety relay cuts power to the motor when the Emergency Stop signal is lost from the Showstopper Emergency Stop Input.

To recover from an Emergency Stop fault, check any of the following:

  • The Showstopper Base shows a .

  • If any Showstopper emergency stop buttons are activated, release them.

  • Confirm that a Showstopper emergency stop cable is connected between a Showstopper Base/Hub and the Stagehand Emergency Stop Input.

  • Swap the Showstopper emergency stop cable in case of a faulty cable.

  • With a multimeter, check for 24VDC on pins 1 & 5 of the Showstopper emergency stop cable. If everything above checks out and you don't see 24VDC, there's a wiring problem somewhere between the Showstopper and the safety relay in the Stagehand. Contact support.

Limit Faults

The Stagehand registers a limit fault when a corresponding control signal is lost from the Sensor Input. First, verify a cable is attached between the machine and the Sensor Input.

If the cable is plugged in, here's the next recovery options:

Reverse Limit

  • Drive the machine forward using the manual controls until the fault is cleared.

  • Temporarily press the REV limit override button to continue moving in the reverse direction.

Pressing the limit override button defeats the safety of the limit switches. Only qualified personnel should use the limit override buttons, and only use them with caution.

Driving off of a limit switch by running a cue is not recommended. It may sometimes work, but if there is even a single encoder count detected in the reverse direction, the cue will abort.

Forward Limit

  • Drive the machine reverse using the manual controls until the fault is cleared.

  • Temporarily press the FWD limit override button to continue moving in the reverse direction.

Pressing the limit override button defeats the safety of the limit switches. Only qualified personnel should use the limit override buttons, and only use them with caution.

Ultimate Limit

Unlike the forward and reverse initial limits, the loss of the Ultimate Limit signal disables motion in either direction. This behavior is intentional. Under normal operation, an Ultimate Limit signal faults only when an initial limit (forward or reverse) has failed to stop the machine.

Go to the machine. Investigate the cause of the Ultimate Limit Fault. Repair the problem with the initial limits.

You cannot jog off of an Ultimate Limit switch to clear the fault. Your options are:

  • Mechanically adjust the position of the Ultimate Limit switch to clear the fault, if it has been set improperly.

  • Temporarily press the ULT limit override button to move in a safe direction.

Pressing the limit override button defeats the safety of the limit switches. Only qualified personnel should use the limit override buttons, and only use them with caution.

Further steps

A broken, or disconnected, wire to a limit switch will also trigger the fault. If a limit switch fault fails to clear even after you have performed the steps above, check the following:

  • Swap the cable on the Sensor Input. A bad cable will prevent the limit signal reaching the Stagehand.

  • Inspect the mechanical connection of the limit switch to the machine to verify proper operation.

  • Inspect the internal wiring of the limit switch to verify the limit wires are connected to terminals on the limit switch.

Drive Faults

The Stagehand Motion Controller registers a Drive Fault if it does not sense an "ready" signal from the VFD. Most often, this is caused by an internal fault in the VFD (such as a machine drawing too much current). The most common VFD faults and the remedies can be found here, or in the VFD manual.

Here are some times that you see a Drive Fault that are not really a VFD fault:

  • The emergency stop is engaged. This kills power to the VFD which prevents it from sending a "ready" signal.

  • An internal wiring problem. Contact support.

Resetting a Drive Fault

After digesting the cause of the fault, you can clear the fault any of the following ways:

  • Reset the VFD through Spikemark.

  • Cycle the emergency stop. This cycles power to the VFD which will reset the fault.

  • Press the red reset button on the VFD keypad.

VFD Fault History

Press the MODE button until the VFD keypad displays “E - - -” and you can view the Faults history of the drive. Spin the wheel on the keypad to scroll through the most recent 8 faults.

Brake Fault

The VFD monitors both brake contactors that power the load brake and motor brake. If the output state of the contactors doesn't match the commanded state, the internal "brakes OK" signal from the VFD to the motion controller is dropped.

For example, if the VFD tries to remove power from the brakes, but the contactor output is still allowing power to pass through, the contactor has welded shut. The VFD can sense this issue and disallow any further motion until the contactor is repaired or replaced.

Here are some times that you see a Brake Fault that are not really a Brake fault:

  • The emergency stop is engaged. This kills power to the VFD which prevents it from sending a "ready" signal.

  • An internal wiring problem. Contact support.

Sadly, if you truly have a Brake Fault, it means that one of the contactors is broken and needs to be sent back to Creative Conners for repair. This has yet to happen as of August 10, 2022 at 6:27pm EST since the Stagehand Pro launched in 2015, but someday I bet it will. We're ready — Contact Support.

Cross-Groove Fault

When the Cross-Groove signal is lost from the Sensor Input, the Stagehand registers a fault and stops all motion. The intention is to stop a winch or hoist, once the wire rope has jumped a groove on the drum, before a dangerous hazard arises.

To recover:

  1. Go to the machine and inspect the wire rope for damage.

  2. Press and hold the Sensor Override button.

  3. Jog the machine in the proper direction to clear the jumped wire rope.

If the cross-groove sensor is not activated, check the wiring of the sensor. A disconnected wire to the cross-groove sensor will also trigger the fault.

Cross-groove faults often indicate improper rigging of the winch or hoist. The first mule, or diverter pulley, is either poorly aligned or too close to the drum. Move the pulley further from the hoist to reduce fleet angle and improve the alignment.

Load Cell Faults

Through Spikemark, you can set an Overweight Threshold and an Underweight Threshold. The Stagehand will halt motion if the sensed weight from the load cell drops below the Underweight Threshold, or rises above the Overweight Threshold.

To recover:

  1. Determine the cause of the fault.

  2. Press and hold the Sensor Override button.

  3. Jog the machine in the proper direction to mitigate the hazard.

You can turn off load cell faults through Spikemark if you are not using the Load Cell input and experiencing spurious faults. Load cell faults will remain disabled until you reactive them in Spikemark.

The Overweight Threshold prevents the hoist or lift from picking up a load that is too heavy. The Underweight Threshold senses when the load is caught on an external obstruction and is no longer suspended on the hoist.

Interlock Faults

The Stagehand will prevent movement in one or both directions when a corresponding signal is lost from the Interlock Input.

To recover either:

  • Clear the source of the fault

  • Temporarily install the Interlock Terminator

Installing the Interlock Terminator will bypass all interlock sensors and should be done only by qualified personnel using sensible caution.

Release the button.

Release the button.

green Ready light
3MB
A800 Faults.pdf
pdf
VFD Fault List
Sensor Override
Sensor Override