B08_Attachment_6_Controls_O_M_Manual.pdf

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

Equipment Guarantee

Introduction

Operations

Motorized Sets Introduction Basic Operation

SYSTEM STARTUP

PASSWORD LEVELS

SYSTEM STARTUP - STAGE VIEW

Maintenance

Motorized Equipment Maintenance Troubleshooting Powered Equipment

Reference Material

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. J.R. Clancy, Inc.

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.

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.

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

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 Operation

SYSTEM STARTUP

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.

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.

The SceneControl™ 12P (PENDANT) controller is 12” Windows touch screen controllers running the Raynok Motion Control Software in rack mount and remote variants, respectively. The device is intended as a full featured main operator station. With the

SceneControl™ 12 an operator has the ability to run cues, jog machines (with the

SceneControl™ 12 + Expansion) and control an entire Scene Control Motion Control

System with a simple touch screen interface.

The SceneControl™ 12P is a remote device and is connected to a control point in the system via a 25’ or 50’ multi-harness 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™ 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™ 12 is turned on 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.

Maintenance

Drum Hoist Maintenance

GENERAL DESCRIPTION

The J.R. Clancy motorized drum winch is an electro-mechanical system specifically designed to move and hold scenery, lights and other theatrical equipment over the stage. It is designed with safety factors and safety features required of equipment which operates around and over people.

All motorized pileup drum winch systems contain the following:

A. A motor provides the force to hold and move the load. Motors can be fixed speed, two speed, or variable speed and require AC or DC power.

B. A gearbox and/or system of sprockets and roller chains reduces the speed of the motor and multiplies the torque.

C. A drum stores cable and transmits force from the gearmotor to the load.

D. Motor brakes, and sometimes a load brake, stop and hold the load. These are released when power is applied to the motor and applied by fail-safe springs when the motor is turned off.

E. A reversing motor starter or drive controls the flow of electricity to the motor.

F. Limit switches or other devices limit travel.

G. The operating panel allows the operator to control the direction and duration of the travel.

OPERATION

WARNING!

J.R. Clancy winches are NOT designed to hold, raise or lower people and should never be used in this manner.

CAUTION!

NEVER operate rigging without first obtaining proper instruction and authorization.

A. Study the winch status and exact method of operation. Check the load and look for places where the load could foul during operation. Check limit switches and other travel limiting devices for proper operation. Be sure the motor disconnect is turned on.

B. Become familiar with any associated safety devices such as line contactors, emergency stop switches, phase loss or phase reversal relays, slack line relays, etc.

C. See the operation manual for details of the controls and method of operation.

D. The brake is automatically applied when the motor is turned off. However, the load will continue to travel until the motor decelerates to a stop. The distance traveled will depend upon the condition of the brake, the size of the load and whether the load is being raised or lowered.

The stopping distance of a variable speed winch will depend upon the deceleration ramp programmed in the drive. If you are attempting to stop at a certain point, check the stopping distance and then plan ahead.

Spring applied motor brakes provide the primary stopping and holding power for winch loads.

Load brakes provide back-up stopping power near the load on the output side of the drive train.

Load brakes must hold the full load torque of the winch system.

E. Some winches are equipped with an encoder, potentiometer, or other device that provides a position or winch status signal to the control system. The manual or shop drawings provide more data if any of these devices are supplied.

F. GENERAL PRECAUTIONS

1. Keep people out from under moving equipment.

2. Look for potential problems, such as lift lines or curtains which could foul a batten.

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

4. Never load the set beyond the design capacity of the winch system. Reduce the load or re-balance the counterweight carriage as required.

5. During set-up, operate only one set at a time. Identify any potential interferences or other problems.

6. Keep all moving components free of dirt and obstructions.

7. Keep all safety guards in place.

8. Do not override limit switches or other safety devices.

INSPECTION

All electro-mechanical equipment requires periodic maintenance and inspection to insure long life and trouble free operation. Inspect equipment on a scheduled basis and keep records. These will provide information on length of service and any changes which might indicate worn parts.

The frequency of inspections depends on the usage and severity of the operating conditions, but at minimum look for problems (crossed cables, loose fittings, obstructions, etc.) once a month and conduct a full visual inspection and lubricate annually. In addition to inspections and maintenance by the in house staff, J.R. Clancy, Inc. recommends that a safety inspection be performed by a professional stage rigging firm at least once a year.

Before performing any inspection or maintenance on powered equipment, it should be turned off and locked out in accordance with OSHA and/or other guidelines established by your organization. Do not open or remove any protective covers until this step has been taken.

LUBRICATION

Motors

▪ Most motors (Including Eurodrive AC) are sealed and never need lubrication. Some ball bearing motors are shipped with at least six months of grease in the housings and need only a small amount of high grade ball bearing grease added every six months. Over greasing will result in excessive heat.

Pillow Blocks and Flange Bearings

▪ Add grease until the old grease is purged from the bearing seals. Do this with the shaft turning if possible. Lubricate every six (6) to twelve (12) months with a NLGI #2 Lithium based grease such as the following or equivalent:

Amoco Oil Amolith EP LF 2

Castrol Pyroplex Red

Chevron Ultra Duty E.P. #2

Dryden Oil Drydene Lith EP-2

Exxon Beacon 325

Unirex 3

Mobil Mobilith AW 2

Phillips 66 Philube L2 & EP

Shell Alvanta 3

Texaco Lubricants Multifax EP 2

Roller Chain

▪ Use multipurpose #2 oil.

▪ Oil should be periodically applied to the upper edges of link plates in the slack or lower span of the chain using a brush or oil can. Oil should be applied after about every 8 hours of operation or often enough to prevent a reddish-brown or rusty discoloration of oil in the chain joints. The rusty discoloration indicates that joints are becoming dry.

▪ Do not allow roller chain to operate in an un-lubricated condition. Use good quality, non-detergent, petroleum-based oil that flows freely into chain joints at the normal operating temperature. See chart for recommendations:

OPERATING TEMPERATURE

(Deg F)

RECOMMENDED

LUBRICANT

20 - 40 SAE 20

40 - 100 SAE 30

100 - 120 SAE 40

▪ When drives are serviced, the lubrication system, drive alignment, chain tension, chain and sprocket wear, and drive interference should be checked. If the chain is dirty, it should be cleaned with solvent (be careful to use solvents that do not damage plastic or other parts that may come in contact with the solvent) and re-lubricated. Check chain tension by measuring the amount of chain movement in the slack span as follows:

RECOMMENDED MID-SPAN MOVEMENT IN CHAIN SLACK SIDE

DISTANCE BETWEEN

SPROCKETS (Inches)

DRIVE CENTER LINE

0 to 45 Degrees 45 Degrees to Vertical

10 0.25” 0.12”

20 1.00” 0.50”

30 1.50” 0.75”

60 3.00” 1.50”

▪ Check chain wear by measuring chain length over the number of pitches nearest to 1 foot. If that measured length is 3 percent (approximately 0.36 inches) over normal, the chain is worn and should be replaced.

Gearboxes

▪ Check oil level and quality frequently. Add oil as needed and change if contaminated. Replace after two years or 5000 hours of use. If using synthetic oil, change after four years or 40,000 hours.

BRAKES

▪ As brake disks wear they will no longer stop the motor as quickly as when new. Follow the maker's specific recommendations for adjustment or replacement of brake disks.

▪ Load brakes can take many forms. Carefully review all documentation before making any adjustments. Contact the factory for assistance.

▪ Once each year, the adjustment bolts on overspeed brakes should be checked and retightened to the torque listed on the brake label. If the label is missing or the torque not listed contact

JR Clancy. Failure to check adjustment blots may result in the brake failing to stop the load.

MECHANICAL COMPONENTS

▪ Check and tighten, if needed, all couplings, set screws, etc. frequently. Include the coupling between the motor and the gearbox in your inspection, if it exists.

▪ Clean motor and gearbox fans to keep them from overheating.

▪ Components in starter cabinets should be checked two or three times per year. Be sure the power is off before opening the control cabinet for routine maintenance. Excessive dirt should be vacuumed from the cabinet interior to prevent contact arcing and premature relay failure.

▪ Keep safety guards in place except when access is required for service

LIMIT SWITCHES

▪ Rotary limit switches should be checked annually (at least) for adjustment and the roller chain lubricated. The switches and roller chain drive must be kept clear of obstructions at all times.

See the manufacturer's data sheet for instructions.

▪ Direct-stuck switches should be checked for adjustment periodically, adjustment screws kept tight, and the switches kept clear of obstructions at all times.

MOTOR STARTERS

▪ Components in motor starter cabinets should be checked two or three times per year.

▪ Excessive dirt should be vacuumed from the cabinet interior to prevent contact arcing and premature relay failure.

▪ Screw terminals can work loose over time from heating and cooling due to current flow.

Periodically check that all screw terminals are tightened to the proper torque.

▪ Fuses will occasionally fail from age or build up of stress. Replace failed fuses only with fuses of the same type and rating. Be sure to check the rating on the failed fuse and the label at the fuse block or shop drawing. If the fuse has the wrong value, replace it with a fuse of the correct type and rating. If a fuse fails a second time, look for a short circuit or defective component. The following chart lists fuses commonly used in Clancy starters. Be sure to check the rating.

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

Be sure the power is off before opening the control cabinet for maintenance.

▪ NOTE - Your specific system may contain some equipment or items not listed above. If so, individual data sheets from component manufacturers have been included in your manual. For additional maintenance instructions or in case of questions, please consult the factory.

PARTS LIST

▪ Consult J.R. Clancy shop drawings for listings on specific components.

SELF-PROTECTED STARTER

▪ Most 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.

▪ The self-protected starter is modular in construction. Modules containing auxiliary contacts are added to the starter for various purposes, including fast actuation of motor brakes and external fault annunciation.

▪ Terminals at the top of the starter accept the starter’s input power.

Terminals at the bottom of the starter are used to connect the starter output power to the motor. Control terminals on the reversing module at the bottom of the starter accept control signals to actuate the contactors within the starter.

▪ The starter components are selected for the motor size and current requirements, and for the required control system voltage.

LIMIT SWITCHES

▪ Most hoist systems are provided with two types of travel limits: operational limits and overtravel limits. Intermediate limits may also exist in some systems. Consult your system drawings.

▪ Operational limits control the distance the load will travel (both up and down) under normal conditions, such as the normal low and high trim (positions) of a load. These should be set within the limits established by the overtravel limit switches. Operational limit switches may be re-adjusted by trained personnel to suit changing conditions.

▪ Overtravel limits are intended to protect the building and equipment against damage from excessive travel of the hoist system. These limits are often called the “ultimate” limits.

Overtravel limits are usually set within a few inches past the operational limits. These and other safety devices are set at installation and should be tested occasionally (see maintenance data), but never changed to suit temporary needs.

▪ NOTE: In most systems, the hoist cannot be operated if an overtravel limit has been activated. If this occurs, an overtravel bypass switch is located in the motor starter cabinet.

Striking an overtravel limit indicates that the primary operational limit has failed. The system should be inspected and repaired if necessary. Contact the factory if assistance is required.

Ravasi Rotary Limit Switches

1. Establish Rotation

▪ Remove limit switch cover.

▪ Drive hoist in UP direction - note direction of cam stack rotation.

▪ Mark switch cover or label inside switch to record cam stack rotation.

▪ Avoid contacting screw terminals on operating switches while hoist system is on.

2. Determine Travel

▪ Determine where load must stop to avoid damage/misalignment - set overtravel to stop short of this point.

▪ Determine the range of travel required for the load; set normal limits to stop load at these points.

▪ For each end of travel, set overtravel limit first, then set end-of-travel limit.

▪ Before running tests, make sure that the operator can clearly see the entire load for its entire travel, or that spotters are in place to observe and clearly communicate with the operator.

3. Adjust Limit

▪ Drive the hoist to the desired end of travel.

▪ Re-verify cam stack rotation (when the hoist travels up, does the cam stack rotate clockwise or counterclockwise). Determine which side of the desired switch the limit cam must strike (i.e.

if the cam stack rotates clockwise when the hoist travels down, and you are setting a down limit, the cam must actuate the down limit while moving in a clockwise direction).

▪ Loosen the central cam stack clamping screw (1/2 turn).

▪ Locate the adjusting screw for the desired limit by referring to the numbers adjacent to the adjusting screws. Note that the lowest switch in the cam stack (down overtravel) is switch 1, the next switch (down limit) is switch 2, the next switch (up limit) is switch 3, and the highest switch in the stack (up overtravel) is switch 4.

▪ Rotate the adjusting screw to adjust the limit cam lobe to a position where the selected limit switch is just actuated (audible click).

▪ Once the limit cam is at the proper place, tighten the cam stack clamping screw.

4. Test Limit

▪ Drive hoist away from limit until limit is cleared (use overtravel bypass switch to move hoist off overtravel limit).

▪ Drive hoist toward limit until limit stops motion.

▪ Assess stopping position (measurement vs. target).

▪ Drive hoist off limit (use overtravel bypass switch to move hoist off overtravel limit).

5. Refine Limit Adjustment

▪ Repeat the Adjust Limit procedure, as detailed above.

▪ Move cam lobe closer to switch to make switch trip sooner (decrease travel distance).

▪ Move cam lobe further from switch to make switch trip later (increase travel distance).

▪ Make sure to tighten cam stack clamping screw after each adjustment!

▪ Retest limit adjustment until hoist stops at desired position.

6. Adjust Remaining Limits

▪ Once overtravel limit is set, set normal limit at same end of travel.

▪ Check to ensure that there is sufficient distance between normal limit and overtravel limit - if the hoist strikes both limits before stopping, increase the distance between the limits by moving the normal limit to stop the load sooner.

▪ Once all limits are set, check that cam stack clamping screws are tightened, then replace the limit switch cover.

Direct Struck Limit Switches

▪ These limit switches are located in the path of travel of the load, or next to the tracks used to guide a counterweight arbor. When the load or arbor contacts a movable arm on the limit switch, the hoist (and load) will stop.

▪ There are normally four (4) limit switches for each system, representing the travel limits (i.e.

Ultimate down, Down, Up, and Ultimate Up). These limits are made up of a switch body with an adjustable length lever arm with a roller that will contact the load as it passes by. As the lever is moved, the power to the hoist is shut down.

▪ Direct-struck limits are often mounted to Unistrut channels to allow for adjustment

▪ To install and set a direct-struck limit switch, follow these general guidelines:

a. Securely mount limit switches so that the body of the limit switch is not in the path of arbor or piece travel and will not move when the switch arm or plunger is struck. They should be protected against accidental damage.

b. Wire the switches with flexible connections so that the switches may be moved for adjustment.

c. To adjust the travel limits, loosen the plate attaching the switch to the Unistrut channel.

Slide the switch as required to the proper position, and re-tighten the channel bolts.

d. The length of the lever arm may be adjusted by loosing the screw at the switch head.

Position the lever arm for best operation. Re-tighten the screw at the switch head.

e. Set the operating arm or plunger so it will not be damaged by overtravel of the system as it slows down and/or stops.

Overtravel Limit Bypass

▪ Clancy motor starters are equipped with momentary toggle switches to bypass the overtravel limits as an aid to switch setting and restoring normal operation after a failure. The motor may be able to operate in either direction when the overtravel bypass switch is being held closed.

ENCODERS

▪ Encoders may be supplied allowing the hoist to send data back to the control system indicating where the load is located in the path of travel. Encoders may be driven off the output shaft of the hoist drum or be directly mounted to the motor shaft. Consult the system wiring drawings for details, including routing and type of cabling. Do not splice wires. Consult the factory before making any changes to the suggested wiring.

Be sure of the intended direction of operation before pushing any button to run the machine using the overtravel bypass switch.

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.

CAUTION

▪ Electrical hazard.

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

“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 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.

I. 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

J. 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.

K. 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.

L. 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.

Brake rectifier defective – replace (see brake motor manufacturer’s literature).

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…