Creative Conners Safety Interlock Pro User manual
Safety Interlock Pro ™
Reference Manual v1.0
Copyright 2020, Creative Conners, Inc
Safety Interlock Pro Reference Manual 3/2020
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Safety Interlock Pro Reference Manual 3/2020
Contents
Contents 3
Getting Started 4
What’s Included 4
Features 5
Installation 5
Powering Up 6
Signal Connections 6
Limit Connections 6
Sensor Connections 7
Emergency Stop Connections 7
Operation 8
Troubleshooting 8
Common Problems 8
Technical Support 9
Phone 9
Email 9
Specifications 9
Electrical Specifications 9
Drawings 10
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Safety Interlock Pro Reference Manual 3/2020
Getting Started
The Safety Interlock Pro is an extra layer of safety to critical effects. Integrating bumper switches,
pressure mats, and additional limit switches into any system gives a secondary layer of protection for
areas with potential pinch points, like an elevator or pivoting wall. The Safety Interlock is wired
between the machinery and the Stagehand with simple, pluggable connections to interrupt either
forward or reverse motion.
This manual will guide you through:
●Unpacking
●Installation
●Powering up
●Operation
●Troubleshooting
If you need any help along the way, contact us on our website (creativeconners.com), via email
What’s Included
In the box you will find:
●Reference manual (this document)
●Safety Interlock Pro
●Two 3-pin XLR jumpers
●Six limit jumpers
If any of these parts are missing, please contact us.
If you ordered any bumper switches or pressure mats those items are packaged separately.
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Safety Interlock Pro Reference Manual 3/2020
Features
The Safety Interlock Pro is a 3U rack mountable device with 4 mounting holes. Listed below are
additional features of the Interlock.
1. Three indicator lights to show the status of the Safety Interlock
2. Signal input from the Stagehand Pro
3. Signal output to the machine
4. Two ultimate limit outputs, two forward, and two reverse
5. Forward and reverse sensors (one input and output for each direction)
6. Emergency stop input and output
Installation
The Safety Interlock Pro is a 3U rack mountable case designed to fit in a standard 19” rack. It is not
required to be rack mounted, feel free to place it on the operator desk or with the Stagehand Pro
motion controllers.
A key point to note during installation is that the Safety Interlock Pro will need to be connected
between the machine and the Stagehand.
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Safety Interlock Pro Reference Manual 3/2020
Powering Up
After the Safety Interlock is installed, it is time to power it up and test that bumper switches, pressure
mats, and/or limit switches are working correctly. The Safety Interlock Pro requires 24VDC from the
showstopper circuit in order to receive power.
Signal Connections
The Stagehand controller sources 12VDC on a pin of each limit circuit and expects to see that 12VDC
signal returned on the other pin when the limit is not activated. If the limit is activated, disconnected,
or a wiring fault occurs, the 12VDC return signal is interrupted and the Stagehand Pro will enter a limit
fault condition and disallow motion.
Adding a safety interlock pro to a Stagehand Pro allows additional limit switches and safety sensors
to be monitored. These switches and sensors interrupt the forward, reverse, and ultimate limit circuits
coming from the machine.
The limit switch inputs are used to protect against the motor traveling too far in a direction and
causing damage or injury.
Limit Connections
The Stagehand Pro motion controller monitors forward, reverse, and ultimate limit circuits. The
auxiliary limit connections place additional limit connections in series with those already connected to
the Stagehand Pro.
Diving a little deeper into limit signals:
●Ultimate Limit – a pair of switches can be wired in series to this pair of terminals to provide
protection against Forward and Reverse Limit switch failures. Traditionally, these switches are
wired Normally Closed (N.C.) but can different depending on the application. Typically, an
Ultimate Limit switch is positioned just beyond both the Forward and Reverse Limit switch. If
any Ultimate Limit is activated, the Stagehand will disallow any further movement until the limit
is physically cleared. An Ultimate Limit signal indicates an equipment problem with at least one
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Safety Interlock Pro Reference Manual 3/2020
of the primary limit switches. The faulty equipment must be repaired, and the Ultimate Limit
must be mechanically reset before the Stagehand will allow motion.
●Reverse Limit – If any Reverse Limit switch is activated, the Stagehand will not allow further
motion in the reverse direction until the limit is cleared either by adjusting the switch
mechanically or by moving in the forward direction far enough to clear the limit switch.
Traditionally, these switches are wired Normally Closed (N.C.) but can different depending on
the application.
●Forward Limit – If any Forward Limit switch is activated, the Stagehand will not allow further
motion in the forward direction until the limit is cleared either by adjusting the switch
mechanically or by moving in the reverse direction far enough to clear the limit switch.
Traditionally, these switches are wired Normally Closed (N.C.) but can different depending on
the application.
Sensor Connections
The safety interlock adds additional support for 4 wire safety circuits (e.g. bumper switches, pressure
mats). A 4 wire safety circuit when used in conjunction with a safety relay allows monitoring for the
following four conditions:
1. Disconnected - the safety relay sends out test pulses through the sensor and expects the
signal to return. If that signal does not return the safety relay will go into a faulted state and
disallow any further motion.
2. Shorted - if a wire has been crushed by equipment or cut the safety relay will go into a faulted
state.
3. Cross Circuit - if the signals get crossed and the test pulse comes back on the opposite
channel the safety relay will go into a faulted state.
4. Good - if none of the above conditions occur the safety relay will not prohibit any movement.
Emergency Stop Connections
The Safety Interlock Pro requires a 24VDC Emergency Stop signal from a Showstopper in order to
allow power to flow to the motor and brakes. Internally, the Stagehand controller has a redundant,
self-monitoring circuit to insure that power will be removed from the motor and brakes instantly if the
24VDC Emergency Stop signal is interrupted. The 5-pin XLR cable is not a DMX signal, but rather it
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Safety Interlock Pro Reference Manual 3/2020
was chosen as a convenient cable that is prevalent in many venues so you should always be able to
find a spare cable when needed.
Below is the pin-out for the Emergency Stop input:
Operation
Once powered up, the Safety Interlock Pro is operational. If all of the connections have been properly
made, the entire system is powered up, and none of the sensors or limit switches are activated, the
Safety Interlock Pro is actively doing its job. To verify this, the three indicator lights on the face should
all be illuminated. Other than connecting or disconnecting any limit switches or sensors, there should
be nothing else that needs to be done to the Safety Interlock itself.
Troubleshooting
When encountering an issue with the Safety Interlock Pro, the first thing to check would be that none
of the limits or sensors are activated. If they are not, the next thing to check would be that all of the
cables or jumpers are connected properly. If all connections are made properly and none of the
sensors or limits are activated it would be best to make sure that none of the cables have been cut or
damaged.
Common Problems
The issue that is most often encountered is leaving an open connection. All connections on the back
of the interlock need to have a physical cable or a jumper plugged in. Making sure that either the
cables or the jumpers are seated properly is also important. It is common to mix up the sensor input
and outputs in the forward and reverse direction.
Condition
Remedy
No indicator lights illuminated
Check main power
Only Power and REV safety sensor indicators
illuminated
Confirm no FWD limit is activated
Confirm no FWD sensors activated
Confirm they are plugged into correct direction
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Safety Interlock Pro Reference Manual 3/2020
Only Power and FWD safety sensor indicators
illuminated
Confirm no REV limit is activated
Confirm no REV sensors are activated
Confirm they are plugged into correct direction
Only Power indicator illuminated
Confirm no limit is activated FWD and REV
Confirm no sensor is activated FWD and REV
Confirm they are plugged in to correct
corresponding direction
Technical Support
Despite our best efforts and intentions to provide reliable equipment and clear instructions, there
may come a time that you need more direct, personal help. We are happy to do that too. Please get
in touch in whatever way is most convenient.
Phone
You can reach us weekdays from 8:30am – 5:00pm EST at 401-289-2942. We keep our eyes (and
ears) open even outside of normal business hours because we know rehearsals and performances
usually start after 5pm. If we do not answer your call immediately don’t despair – leave a message,
we are diligently checking voicemails and will call back as soon as possible.
Email
Email is a very convenient tool for technical support, whether you are experiencing a
rehearsal-stopping issue or a less critical problem. Emails sent to [email protected] are
distributed to the entire tech support staff, ensuring the quickest response possible. If you are
encountering an issue with a specific cue in a show, please email the show file along with the
relevant log file from Spikemark with a description of the issue and ideally a date and time of the
incident. We respond within 24 hours, though usually it’s only a matter of minutes.
Specifications
●Inputs for both Forward and Reverse safety sensors (bumper switches or pressure mats)
●Pass through connections for Stagehand Limit Switch signals
Electrical Specifications
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Description
Value
Emergency Stop Input
24VDC
Emergency Stop Output
24VDC
Drawings
Schematic
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