B08_Attachment_5_Quick_Start_Controls_O_M_Manual.pdf

Quick Start Controls Operation &

Maintenance Manual

WOLF TRAP NATIONAL PARK FOR THE

PERFORMING ARTS

Vienna, VI

MANUFACTURED & INSTALLED BY

www.wengercorp.com

WARNING

Equipment not designed or built for lifting people.

▪ Do not operate without proper training and authorization.

Improper use can lead to serious injury.

▪ Read equipment manufacturers manual and this material before using this system. Follow manual instructions to avoid possible serious injury or death.

http://www.wengercorp.com/

Wolf Trap National Park for the Performing Arts, Vienna, VI

Operation & Maintenance Manual

Project Information

Introduction

Operations

Motorized Sets General Information General Precausions

Operating Precausions

Motorized Rigging Control and Operation Introduction Basic System Information

System Passwords at Turnover to Owner Password Levels Basic Information Suggested Safety Procedures

Quick Start Guide Console Startup

Log In

Console Shut Down

Console Operation

Air Conditioning Control

Troubleshooting Powered Equipment

Maintenance and Seasonal Shut Down

Project Information

WOLF TRAP NATIONAL PARK FOR THE PERFORMING ARTS

RENOVATION THEATRICAL STAGE RIGGING MACHINERY SYSTEMS

Vienna, VI

Date: May 18, 2021

Project Number: 10000496

Introduction

RESPONSIBILITY

Anyone who enters a building with public access has reason to expect that he or she is safe from harm from the building itself and from the equipment and activities within the building. It is the responsibility of the owner and the owner’s designated personnel to ensure that this expectation is met.

It is the responsibility of the owner to hire and train competent people. There is a further responsibility to engage professional clients and contractors. A competent person is defined as one who is capable of identifying existing and predictable hazards in the workplace, and who has the authority to take prompt corrective action to eliminate those hazards. It is the further responsibility of the owner and the owner’s designated personnel to provide a safe working environment for all employees; including proper equipment, training on the use of equipment, and written procedures for its use and maintenance. It is also important to keep all unauthorized and/or untrained personnel from the working areas of the stage.

OPERATION

Before operating any stage equipment, operators must be given the necessary training and must then work only under the direction of qualified supervisors. Operators of the equipment must:

▪ Learn the feel, sound, and even the smell of your equipment so that you will immediately sense when something is not correct.

▪ Study the capacities and capabilities of each system and its components.

▪ Thoroughly learn and practice the proper operating procedures.

▪ Before operating any equipment, ask yourself questions about the current condition of the equipment and about any existing conditions which may affect proper operation or which could be affected by its operation. For example, is anything fouling the equipment or in the path of its intended travel?

Any problem noticed during setup or operation of the stage equipment should be corrected

IMMEDIATELY.

MAINTENANCE

Published OSHA and ANSI standards, together with local and regional regulations, call for at least an annual inspection of industrial winch and hoist machinery. There does not appear to be any basis for assuming theatrical winches and systems should be treated any differently and regular inspections on at least an annual basis are required unless the owner’s manual specific to the system recommends a different, more frequent, inspection interval.

A routine maintenance schedule must be established and followed and appropriate records maintained. Perform an initial inspection, followed by inspections on a regular basis. We strongly recommend that an Entertainment Technician Certification Program (“ETCP”) Recognized

Employer employing ETCP Certified Riggers be engaged to perform periodic inspections and to correct any deficiencies discovered. These firms have personnel who are trained to spot present hazards and many “potential” hazards.

Routine maintenance prolongs the useful life of equipment and keeps it operating at peak efficiency. This insures the quietest possible operation and the least effort on the part of the operator.

DISCLAIMER

The information in this manual will not cover all possible situations, nor could such inclusive instructions be written by the equipment manufacturer due to the various processes of mounting theatrical performances. This manual is intended to provide a guide to the safe and efficient operation of the furnished stage equipment and its routine maintenance. No manual can replace your duty to obtain training with regular updates, exercise constant vigilance and common sense. Wenger is not responsible for any damage that results from your failure to comply with this manual.

Operations

Motorized Sets

Machine may be remotely controlled.

▪ Inattentive or untrained operation can result in serious injury or death.

▪ You are responsible for:

▪ The safety of those around you.

▪ Identifying and evaluating hazards.

▪ Determining and using correct methods of operation.

GENERAL INFORMATION

Motorized hoist systems contain the following:

▪ A motor provides the force to move the load. Motors may provide a fixed speed or a variable speed depending on the controls specified.

▪ A motor brake to stop and hold the load. The brake is contained in the motor housing. It’s released when power is applied and engaged by springs when the motor is turned off.

▪ A secondary brake as required

▪ A gearbox reduces the speed of the motor and multiplies the torque.

▪ A drum, shaft, or sprocket transmits the force to the load.

▪ A fixed speed hoist has a reversing starter which controls the power to the motor, and the direction of rotation. A variable speed hoist has a solid state drive controlling the power to the motor.

▪ Limit switches or other devices limit travel.

▪ An operating panel allowing the operator to control the direction and duration of the travel.

▪ Your system drawings provide additional information about the specific electrical and mechanical components in your hoist.

CAUTION

▪ Do not operate without proper training and authorization.

▪ Read equipment manufacturers manual before using this system.

Failure to do so can result in serious injury or death.

Become familiar with the hoists, all control components, and safety devices. These include limit switches, motor disconnects, line contactors and emergency stop switches, plus any optional devices, such as phase loss or phase reversal relays, slack line relays, etc. Know where these are located and how they function. See the Troubleshooting section for additional details.

GENERAL PRECAUTIONS

▪ Pay attention to what is happening around you. “THINK”

▪ Always look around when entering the stage house, especially up.

▪ Remove unnecessary items from your pockets and belt.

▪ Secure any needed tools to your body before going above the stage floor.

▪ Wear a hard hat when “SETTING” or “STRIKING” a show.

▪ Wear heavy-duty work gloves.

▪ Wear safety shoes.

▪ Do not wear loose fitting clothes and jewelry.

▪ Secure long hair.

OPERATING PRECAUTIONS

Check the load and look for places where the load could foul during its travel.

Ensure the hoist is not loaded beyond its capacity.

The operator must constantly watch the progress of the load being raised or lowered. If the operator cannot see the load, a spotter should be stationed to watch and report its progress to the operator.

There must always be a floor or "safety" person present on stage when sets are operated in order to:

▪ Keep people out from under moving equipment.

▪ Look for potential problems, such as lines or curtains which might foul a batten.

▪ Make sure that proper operational and safety procedures are followed.

▪ Identify any potential interference or other problems.

During set-up, operate only one set at a time.

Motorized Rigging Control System Operating Manual

Introduction The J.R. Clancy SC12 is a sophisticated, microprocessor-based system, used for controlling motorized stage rigging. It uses a touchscreen operator interface, and offers simple modes of operation for rapid, easy use. A number of powerful features provide greater flexibility of operation for more sophisticated operators.

The control system is designed to enable the safe operation of the motorized rigging. It is crucial that, before operating any stage equipment, all operators should be given the necessary training and should then work only under the direction of qualified supervisors. Stage equipment can be hazardous when improperly operated and maintained. Never use the system to lift people!

While there are a number of principles that guide the safe operation of rigging equipment, there is one that will be reiterated throughout this manual:

WATCH THE PIECE!

Whenever a set, batten, hook, or other piece is being moved by the motorized rigging system, make sure that the operator can see the entire piece throughout its path of travel. If the operator cannot see the entire piece, or the entire path, then spotters must be positioned to supplement the operator's view. All spotters must be in clear and reliable communication with the operator throughout the move. This is the level of vigilance that is necessary to safely operate rigging equipment.

Whenever you see the words “WATCH THE PIECE!” take a second to make sure you are paying attention to the important stuff - the moving iron, not the flashing pixels!

While the information in this manual will not cover all possible situations, nor due to the nature of theatre could such instructions be possibly written, it is intended to provide a guide to the safe and efficient operation of the furnished stage equipment and its routine maintenance. No manual can replace constant vigilance and common sense.

A routine maintenance schedule should be established and followed, and appropriate records should be maintained.

▪ Learn the feel, sound, and even the smell of your equipment so that you will immediately sense when something is not correct.

▪ Study the capacities and capabilities of each system and its components.

▪ Thoroughly learn and practice the proper operating procedures.

▪ Before operating any equipment, ask yourself questions about the current condition of equipment and about any existing conditions which may affect proper operation, or which could be affected by its operation. For example, is anything fouling the equipment or in the path of its intended travel?

Further, any problem noticed during setup or operation of the stage equipment should be corrected

IMMEDIATELY. Someone’s life could be at stake.

We suggest that emergency procedures be established in case of fire or injury and that periodic drills be held.

In addition to routine maintenance, we strongly recommend that a qualified rigging firm be engaged to perform periodic inspections and to correct any deficiencies discovered. These firms have personnel who are trained to spot present hazards and many “potential” hazards. Routine maintenance also prolongs the useful life of equipment and keeps it operating at peak efficiency for the quietest possible operation and so that less effort is required on the part of the operator.

Basic System Information

SYSTEM

The SC12 system uses a system of distributed microprocessors that communicate with each other over a network system. On startup, the main processor queries the microprocessor at each starter;

therefore, all of the starters must be able to communicate at startup. The steps required to start the system are:

▪ Release the Emergency Stop button at the console and assure that all other system Emergency

Stop buttons are released.

▪ Turn on the power key switch at the console

The system will go through a boot up routine. During this routine, the program will be loaded and all of the hoists will be interrogated by the controller. While this boot up is going on, the following message will appear on the screen:

▪ To be operated by trained and authorized personnel only.

▪ Always maintain direct visual contact with moving sets. Do not watch the screen.

▪ Safety devices do not completely eliminate the risk of injuries.

Always pay attention.

▪ Read and follow safety instructions in Operation and Maintenance Manual.

Once the boot up routine is complete, the legend “Accept” will appear at the bottom of the screen, along with a “Yes” button. Touching this button will take the startup to the next step.

If the system has been configured without a password, then the system will boot up into Access

Level. If the system has been configured with a password for Access Level, then upon boot-up a keyboard will pop up on the screen as a prompt to enter a password. The password entered will determine the user's operator privileges by password levels.

PASSWORDS AT TURNOVER TO OWNER

At turn-over, the user level names are the same as the passwords for those levels, including letter case.

PASSWORD LEVELS

There are four password levels, which are used to regulate access to the control system.

They are as follows:

ACCESS LEVEL - User can perform the following:

▪ move a set Up or Down in deadman operation

▪ create and move a Temporary Preset

▪ load and move a recorded Preset or Cue

Note: the borders are blue while in Access Level.

EDIT LEVEL - in addition to Access Level features, user can perform the following:

▪ Select and load a show previously saved

▪ create a new show

▪ delete an existing show

▪ edit show specific soft upper and soft lower limits

▪ record, edit, and/or delete presets and cues

Note: the borders are gold while in Edit Level or above.

SYSTEM LEVEL - in addition to Access and Edit Level features, user can perform the following:

▪ create, delete, edit sets

▪ edit motors

WENGER LEVEL - in addition to Access, Edit and System Level features, user can access certain system base parameters. This level must only be used by factory-trained maintenance personnel.

BASIC INFORMATION

The SceneControl™ 10 (RACK) and SceneControl™ 12P (PENDANT) controllers are 10” and 12” Windows touch screen controllers running the Raynok Motion Control Software, respectively. The devices are intended as a full featured main operator station. With the

SceneControl™ Controllers, an operator has the ability to run cues, jog machines and control an entire Scene Control Motion Control System with a touch screen interface.

The SceneControl™ 10 is a rack mounted device with 30’ remote pendant.

The SceneControl™ 12P is a remote device and is connected to a control point in the system via a 30’ cable.

To use the SceneControl™ 12 unit, plug the power, ethernet, and Emergency Stop Connector to the closest Control Point. One power button on the bottom of the unit turns the PC/touch screen on, while another power switch enables communication to the Emergency Stop System via an embedded controller on a circuit board.

Once connected properly to the control system the SceneControl™ 10 or 12 can be used to JOG specific equipment, edit and execute cues, and create and execute Manual Move Cues via the installed Raynok Software. For further information regarding Raynok Software, consult the Raynok Software Manual.

When the SceneControl™ 10 or 12 is turned on, control taken and communicating with the motors in the system via Raynok, it is ready to send GO commands. Other controllers in the system can also control machinery, so it is advised to set up various rules for all the control devices within the Raynok Software. Consult your Raynok administrator or the Raynok

Software Manual to take advantage of this functionality.

This document is a quick reference guide for the SceneControl™ 12 and explains the features, functions, buttons and operation of the various unit types. Please read the document carefully and practice safe operating procedures.

SUGGESTED SAFETY PROCEDURES

There is no safety device more important to any machinery control system than an alert and properly trained operator. All personnel that use this motion control system must be properly trained in its safe operation prior to moving any equipment or machinery via the remote-control system.

To ensure that the operator is properly prepared to engage in the operation of the machinery and equipment that this control system operates, consider these simple guidelines and safety checks.

The list of notes below is just a set of guidelines and should never be taken as the only safety notices to be met. Use this list in conjunction with any performance and safety guidelines provided by the owners of the control system.

Before Operating the System

- Enable the Emergency Stop System

- Reset all axes via the Raynok software

- All axes should report ready in the status column

- Depress the Emergency Stop Button

- All axes should report E-stop in the status column

- Open the E-stop report view and ensure that the local E-stop button is reporting

Properly.

- Reset the system and test any other Emergency Stop buttons that have been identified by your company or management as integral to the safe operation of the system

- Follow any other guidelines that have been outlined by your company management

To safely move a machine or equipment connected to the system

- DO NOT WORK ALONE, controlling this equipment from a remote location can be dangerous, always work with another individual when moving machinery and equipment

- With the assistance of another person, properly trained in the operation of the equipment, stationed in the vicinity of the machinery or equipment to be moved ensure that all equipment and personnel are clear and that there are no collision obstructions

- Understand the limitations of the equipment attached to the machinery

- Do not attempt to run a machine that has the potential to injure personnel who are working on it

- If there are personnel working directly on a machine or it’s attached equipment, disable the axis in the control software and turn off the power to the motor drive

- If your system does not have audible or visual warnings that machinery is in motion, warn all personnel working in the vicinity of equipment being moved that it is about to move via a method approved by your management personnel (i.e.

Verbally call out via a loud clear voice or radio communications “Lineset number 22 standing by to move!!”)

- Once the “GO” button has been depressed and the machinery is set in motion again warn all personnel working in the vicinity of the equipment that has been set in motion (i.e. Verbally call out via a loud clear voice or radio communications “Lineset number 22 moving!!”)

- Maintain your hand in close vicinity to the STOP button

- Stay alert and stay in visual contact with the equipment in motion

- Your attention should only be diverted from the equipment in motion to check the computer screens to verify data pertaining to the current move

- When the equipment has come to a complete stop confirm with the personnel working in the vicinity that motion has stopped.

Quick Start Guide

CONSOLE STARTUP

SC 12 Pendants

1A) Setting up one of the SC12 Consoles

i) Take SC12 Console out of Console storage Box

ii) Bring Console to desired Control Port.

iii) Open the Control Port door

iv) Unplug the Shunt plug from the receptacle at the Control Port.

v) Plug Console Connector into Control Port Receptacle.

vi) Verify that the Console HELM ( the Helm is the portion of the console that includes the Go, Stop button as well as the HTR and Estop ) is on:

(1) The GO and STOP buttons should be lit.

(2) The Helm power button, on the left side of the case, should flash approx. once a second.

(3) If not, press the Helm Power button. It is latching button.

vii) Press the momentary button on the top right of the console enclosure to turn on the

Console Computer. The computer will proceed to boot up after a few seconds.

SC10 Rack Mount

1B) Starting up the SC10R-ROP Console

i) Verify that the Console HELM (the Helm is the portion of the console that includes the Go, Stop button as well as the HTR and Estop) is on:

(1) The GO and STOP buttons should be lit.

(2) The Helm power button, CON, above the screen, should flash approx. once a second.

(3) If not, press the Helm Power button, CON. It is latching button.

ii) Press the momentary button, PC, above the screen the Console Computer. The computer will proceed to boot up after a few seconds.

LOG IN

1) Logging In. With either version of the Console, the operator must:

a) Read and acknowledge the statement on the welcome screen.

b) Select the USER to login.

c) Enter the Password and press enter.

i) For additional information on setting passwords see RAYNOK USER Manger section.

2) Checking the Proper showfile

a) SC10R-ROP – This console uses a separate showfile due to the variation in the screen size.

i) Ensure that the standard showfile, with the appropriate presets is loaded. Typically the last loaded showfile is what is loaded onto the console, but if show specific, or custom showfiles are needed, care should be taken to ensure that the correct, default file, or the custom showfile is loaded.

b) SC12 – This console has two different showfiles, as well as alternate configurations based on what part of the system it is using.

i) Ensure that the standard showfile, with the appropriate presets is loaded.

Typically, the last loaded showfile is what is loaded onto the console, but if show specific, or custom showfiles are needed, care should be taken to ensure that the correct, default file, or the custom showfile is loaded.

3) Going ONLINE with the Console. With either version of the Console.

a) Press the Console OFFLine touch key to toggle the Console to Online mode

b) Touch Yes to accept the Toggle Online Offline mode.

CONSOLE SHUTDOWN

1) Shutting down Console

a) Return to main page in show file.

b) IF changes were made Save show file with Save show file macro and allow a few minutes for show file to save to the Network Attached Storage (NAS) device

Note: Application may show as not responding for a period while saving. This is normal when saving to the NAS backup and the console.

2) Going OFFLINE with the Console.

a) Press the Console Offline touch key to toggle the Console to OFFLINE mode

b) Touch Yes to accept the Toggle Online Offline mode.

3) Powering down the Computer

a) Press the momentary button on the top right of the console enclosure to turn on the

Console Computer. The computer will proceed to close the program and shut down the computer.

4) Powering down the Helm

a) Press the latching button to power down the helm.

5) Disconnect the Console ( SC12 Only )

a) Disconnect the SC12 connector from the control port receptacle.

b) Replace the Shunt plug in the receptacle

c) Close the Control port door.

d) Carefully coil the SC12 cable and return it to it storage case.

CONSOLE OPERATION

1) Moving an Axis from the console

Complete the Console Startup section above if required.

a) From the Multibase1 page, Select the Blue touch key with the label for the desired axis.

b) Verify that the Estop circuit is in a safe state – if the HTR display is red see section below.

c) If the status for the devices on this page is shown as NO RUN PERMIT and the entry in the LOCKED column is blank –

i) Press the Lock to Console touch key and touch yes to lock the axis to the console.

d) if it lists another console in the LOCKED column, see section below.

e) If the Fault Reset is flashing, use that touch key to reset the faults.

There are 3 ways to move an axis Preset, Target, Jog

Preset – recalls a recorded position for that axis, typically the consoles have buttons for (8) presets

Target – enters Manual Cue Mode, allowing the User to enter a temporary target to move to.

Jog – Allows the User to move the axis Up or Down without setting a target.

PRESET - Select the desired preset from list on left hand side of screen.

TARGET – Press the Target touchkey and enter the desired target in the pop-up window.

Confirm the Target value is correct.

JOG – For this option, complete step G first ( HTR ), then press the desired direction

UP / DOWN.

f) Press the Hold to RUN three position switch to the enable / middle position. If properly pressed the following will occur:

i) The axis status will change from Inhibit to Ready.

ii) After a 2 second delay the HTR display on the screen will change from yellow to

Blue.

g) Press the green Go button on Console and the axis will start moving to position.

i) Note: The Hold to Run will need to be held in the middle position during axis movement.

If the HTR is moved to either released, or pressed too hard, the HTR circuit will be dropped, and the axis will stop motion.

h) When completed with movements on this axis.

i) If no further need for motion is expected for this axis, it is best to use the

UNLOCK from Console touchkey to release the axis from this controller.

Note: If properly shutdown, all locks are released from the console.

ii) Press the Close touchkey to return to the MultiBase1 page

Air Conditioning Control

The AC units in the drive cabinets can be turned off when not in use. This can be for an even or seasonally. There are two ways to do this.

1) Console Preset Page allows on and off operation.

2) KeySwitch on E-Stop Cabinets.

It is imperative that the AC units are turned back on when the drives are in use. When shutting down for the season, the E-Stop cabinets with the bypass on them must remain on to keep batteries charged.

See Raynok Control manuals for all other operations and maintenance information.

Troubleshooting Powered Equipment

These instructions are intended primarily for use on J.R. Clancy controls and motor starters, but the principles may be extended to other circuits. When variable speed drives, computer or relay logic controls, or other special equipment is present, look for additional instructions provided by the manufacturer and included in the operation and maintenance manual.

RULES FOR TEST INSTRUMENTS

1. Always read the manufacturer’s instructions first. Save the instructions in a file or safe place for future reference.

2. When using any instrument that has several scales, always start with the highest scale available in order to prevent overloading due to unknowns.

3. Always remove the component to be tested or disconnect the line voltage from the circuit before making any resistance measurements.

4. Never try to use a test instrument beyond its rated capacity.

5. When using a clamp-on instrument, close the jaws tightly around a single conductor only.

Clamping around two conductors neutralizes the fields so no reading can be taken.

6. All test leads must be insulated.

7. All connections must be tight to obtain accurate readings.

8. Check the instrument to be sure that fuses and batteries are in order. If the needle on the ohm scale cannot be zeroed, or if a “low battery” indicator shows, a new battery is needed.

9. In a clamp-on instrument, the upper half of the scale will provide the greatest accuracy.

10. Always apply the basic rules of electrical theory when testing any circuit. Use a DC meter for measuring DC circuits, and an AC meter for measuring AC circuits.

“Rules For Test Instruments” found on page one provides a few tips on the use of test instruments.

However, tips can’t take the place of proper training in their use or in electronic principles.

A. The first step in trouble shooting any circuit is to obtain a clear understanding of the circuit and its function. This does not require a total knowledge of the circuit but does mean you must have a general overall knowledge of the function of the circuit.

B. Next, gain an understanding of the problem. Troubleshooting is very difficult if you do not know what you are looking for. Ask the operator (who uses the equipment) what the problem

CAUTION

▪ Electrical hazard.

▪ Turn off and lock out all power before opening electrical cabinets or beginning any inspection or maintenance work.

is, when did it start, how is it different from normal. Often these answers can help isolate the problem more quickly.

C. ELIMINATE THE OBVIOUS, NO MATTER HOW SIMPLE

1. Is the system control power turned on, and is the E-stop released?

2. Are the power disconnects turned on?

3. Check the fuses, circuit breakers and overload relays.

4. Are limit switches tripped or blocked?

5. Look for overheating or warm areas, signs of leakage, smells, and recently made changes.

6. The check list provided on page 5 may help you to quickly identify a problem.

7. THEN use the following procedures to isolate the problem to the control circuit, power circuit, load, or incoming power.

D. J.R. CLANCY WIRING CONVENTIONS

J.R. Clancy motor starters and controls are furnished with numbered screw terminals for all field wiring connections. All internal wires have wire numbers.

Wires in J.R. Clancy controls and motor starters use the following color code:

COLOR FUNCTION

Black High Voltage Power

Red 120 Volt Control

White AC Neutral

Green Ground

Blue Low Voltage (24VDC) Control

Blue/White 24V Common

Orange Control Power from Remote Device

Table 1

E. TROUBLESHOOTING THE INCOMING POWER SUPPLY, FUSES, AND CIRCUIT

BREAKERS

1. One of the most common troubles found in all electrical circuits is a blown fuse or tripped circuit breaker. This is because the fuse or breaker is sized to open or trip in case of trouble.

The device that has opened or tripped has done so because of some fault. This fault may be located in any load connected to the line, a combination of loads, the wiring, or even the fuse or breaker itself. In any case the fuse must be replaced or breaker reset.

2. Although circuit breakers usually have an indicator to tell when they are tripped, the following test can still be used to test the incoming power to both breakers and fuses.

Before a suspected fuse or breaker is tested, check the incoming power supply for incoming power. It is a common mistake to assume that power is present on incoming lines.

Remember that these lines are also protected by other fuses and breakers that may have tripped or failed for any reason.

3. Use a voltmeter to check the voltage between power legs. In a three-phase system, check the voltage between all phases (A-B, A-C, B-C). The supply voltage should be within 10% of the voltage rating on the motor nameplate and other connected devices. If the voltage is present, but out of specification, further research is needed. If the voltage is correct, check the enclosure for proper ground. To test for ground, connect one side of the voltmeter to an unpainted metal part of the enclosure and touch the other side of each of the line terminals. A voltage difference should be indicated on the voltmeter.

4. Next test the fuses or breaker for an open circuit. Apply power to the fuses or breaker. To prevent any possible feedback through the connected loads, it may be necessary to disconnect the load side of the fuses or breaker. Check the voltage between all phases at the load side of the fuses (A-B, A-C, B-C). If two of these readings are low, check the fuse that is common to both low readings.

To double-check a suspect fuse, remove the fuse from the circuit and connect it to an ohm-meter. Set the meter on the lowest scale. An infinite reading indicates a bad (open) fuse. A zero reading indicates that the fuse has continuity and is good.

F. TROUBLESHOOTING A POWER CIRCUIT

Test each of the incoming power lines with a voltmeter. Voltage must be present and at the correct level. Check between power legs (as described above) and to ground. Do not rely on inductive testers (“wigglers”) for troubleshooting measurements.

G. TROUBLESHOOTING A CONTROL CIRCUIT

1. Eliminate the incoming power as the source of trouble by connecting a voltmeter across the terminals and verifying that the proper voltage is present. Make sure to use the proper reference for measurements (i.e. 24VDC measurements reference 24V common, 120VAC measurements reference AC Neutral).

2. A control circuit flows through a series of devices in its path. Using the wiring diagram as a guide, measure the control circuit at successive terminals in the circuit. If the signal disappears at a point, investigate the device(s) connected at that point.

H. TROUBLESHOOTING LIMIT SWITCHES

1. Rotary limit switches should have:

a. Cover in place

b. Locking screws tight on switch cams

c. Switches making contact with cams

d. Wires tight in terminals

e. Wires free at all other points (not pinched by covers, fittings, etc).

2. Lever type limit switches should have:

a. Levers tight and making contact with cams

b. Wires tight in terminals

c. Switch mountings secure

3. Overtravel Bypass: J.R. Clancy motor starters are equipped with momentary toggle switches to bypass the overtravel limits as an aid to switch setting and to restoring normal operation after a failure. The motor may be able to operate in either direction when the toggle switch is held closed, so be sure of the intended direction of operation before pushing any button to run the machine.

4. FUSES: The following fuse types are normally used in J.R. Clancy equipment. Consult drawings or labels in the equipment for the exact values to be used.

COMMON FUSES IN J.R. CLANCY EQUIPMENT

USE TYPE CHARACTERISTICS

Cabinet mains

Littelfuse CCMR

Ferraz-Shawmut ATDR

Bussmann LPCC

Motor-rated time delay

Transformer Primary

Littelfuse KLDR

Ferraz-Shawmut ATQR

Bussmann FNQR

Transformer-rated time delay

Transformer Secondary

Littelfuse FLM

Ferraz-Shawmut TRM

Bussmann FNM

Fast-acting

Power Supply Primary

Littelfuse 313

Ferraz-Shawmut GDL

Bussmann MDL

Glass ¼’X1’ time delay

Power supply secondary

Littelfuse 312

Ferraz-Shawmut GGC

Bussman AGC

Glass ¼”X1” fast-acting

Table 2

I. PARTS LISTS

1. Consult the J.R. Clancy shop drawings for listings on specific components. Where available, component data sheets will also be provided in the operation and maintenance manual.

J. SELF-PROTECTED STARTERS

Fixed-speed hoists are controlled through the use of a self-protected motor starter. This unit include a disconnect switch to shut off motor power. The disconnect handle is turned to the

“twelve o’clock” position when the power is on, and to the

“nine o’clock” position when the power is off. This handle also functions as a fault indicator; when the handle is in the “ten-thirty” position, it indicates that a power fault has occurred.

The handle must be turned to the reset position (“seven o’clock”), to reset a fault.

The starter contains a control unit with an adjustable overload setting. This dial is set at startup to match the motor’s Full

Load Amperage (FLA), so that the starter will register an

Overload Fault if the current is exceeded.

K. TROUBLESHOOTING CHECKLIST

The table which follows can serve as a check list when looking for difficulties in motor starters. If the unit is variable speed instead of fixed speed, consider the following differences and additions:

1. Variable speed drives use electronic circuitry in the drive instead of thermal overloads.

2. Line reactors and dynamic braking resistors are employed to dissipate power generated during down motion or stopping.

3. The drive monitors a number of fault conditions, including:

a. Over voltage

b. Under voltage

c. Ground faults

d. Over current

e. Over load

f. Power fault

g. Encoder loss

Many drives store faults in an electronic “log” and permit later display of a limited number of faults. See the drive operation manual for details.

4. Vector type drives must have an encoder that monitors the motor shaft. Other variable speed drives may, or may not, employ an encoder.

TROUBLESHOOTING CHECK LIST

PROBLEM POSSIBLE CAUSE REMEDY

No power to motor 3 phase power not present Check disconnect switches at starter and/or motor to insure all are on.

Check main feeder to Motor Starter

Panel for power.

Blown fuse Check fuses at Motor Starter Panel and replace if blown. See problem below.

Power to motor starter but hoist will not run

120 VAC or 24VDC control power not present

Check control fuses. See problem below.

Check control wiring and switches for loose wires or damage. Correct problem and reset as needed.

Thermal overload relay tripped

Reset if necessary. Look for source of condition causing overload. See problem below.

Hoist at end of travel limit switch

Run in opposite direction and reset switch or adjust as needed.

Overtravel limit switch tripped

If hoist is on an overtravel limit, investigate to find source of difficulty. Hoist may be run off overtravel limit switch using the overtravel bypass switch in the starter.

Emergency stop button pressed

Check all system emergency stop buttons to assure they are released.

Pendant E-stop shunt plug not installed

If system uses a control pendant, make sure all pendant receptacles have either a pendant or a shunt plug installed.

Motor hums but does not run One phase of motor power not present

Measure to verify that all 3 phases of power are present. Check power fuses, motor disconnects, terminals.

Motor brake will not release

Fast-acting contacts not wired correctly – verify motor brake connections are complete and match drawings.

PROBLEM POSSIBLE CAUSE REMEDY

Hoist passes through Limit

Switch

Limit switch system failure Check position of limit switches and adjust as needed.

Check whether actuating cams make contact with switches.

Check that all components are secure.

Check that limit switch wires are neatly and securely terminated, without

“stray” strands.

Does switch activation make or break electrical contact? Un-wire switch at terminals and check continuity of

NO/NC contacts.

Defective limit switch Replace limit switch.

Line contactor tripped Emergency stop button pressed

Find out why the E-stop was pressed!

When safe to run, reset the E-stop button.

Overtravel limit switch tripped

See “Hoist passes through limit switch”, above. When safe to run, use the “overtravel bypass” switch as described earlier in this manual.

Thermal overload relay tripped

See problem below.

Blown power fuse or fuses Short circuit in motor circuits

Look for shorted wires or components and reconnect and/or replace components as necessary.

Overload in motor circuits Reduce load on equipment.

Eliminate sources of excessive friction.

Replace worn parts as necessary.

Blown primary fuse on control transformer or power supply

Mains voltage surge Replace fuse.

Component failure Replace control transformer or power supply.

Blown secondary fuse in control transformer or power supply

Short circuit in control circuits

Check for short circuits between control supply and ground – isolate wiring and check external components individually.

PROBLEM POSSIBLE CAUSE REMEDY

Thermal overload relay tripped

High current draw due to overloaded hoist or motor

Reduce load on hoist or other powered device to within the design limit of the machine. Reset the overload relay.

Look for interference in the travel path of the load or a source of excessive friction and remove it. Reset the overload relay.

The overload relay has been set to the wrong current capacity. Adjust the overload to match the full load current rating of the motor.

Excessive heat at relay Increase ventilation or remove external source of heat.

Excessive jogging Pause between activations of machine.

Allow relay to cool between operations. If problem continues, replace relay.

Maintenance and Seasonal Shut Down

The system is designed so that the drive/starter cabinets can be shut down at end of season or for extended periods of time. When shutting down for the season, the E-Stop cabinets must remain on to keep back up batteries charged.

See Raynok Control manuals for all other operations and maintenance information.