ETC Prodigy FlyPipe Studio User manual

Prodigy FlyPipe Studio
Installation Guide
Part Number: 8006M2110 Rev: D
Released: 2020-11

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Table of Contents
Table of Contents i
Introduction 1
Document Conventions 1
Help from ETC Technical Services 2
Overview 3
Safety and Warnings 3
Working Load Limit (WLL) 4
Hoist Specifications 4
Electrical Specifications 4
Interface with Building 4
Lifting Specifications 5
Control and Feedback 5
Hoist Local Controls 5
Initial Hoist Installation 6
Tools Needed 6
Prepare the Installation Location 6
Unpack the Hoist 7
Attach TwinLine Clamps 7
Cable Management 9
Swag Cable Management 9
Install Helix Cable Management 9
Unpack and Prepare 9
Hang Helix from Upper Attachment Points 10
Attach the Platter to the Hoist 11
Attach Cable Assembly to Platter 12

Finalize Hoist Installation 13
Run Power and Data 13
Emergency Stop Termination 14
Verify Proper Wiring 15
Terminate Lift Lines to the Drum 16
Step 1:Move the Drum to Top Dead Center 16
Step 2: Thread Lift Lines Through SafeStop and Drum 16
Step 3: Attach Stop Sleeves to Lift Lines 17
Step 4: Finalize Lift Line Termination 17
Ensure SafeStop Devices are Open 18
Float the Hoist 19
Level the Hoist 19
Configure and Test Hoist Operation 20
Verify Hoist Function 20
Travel Limits 21
Set and Test your Limits 22
To Set and Test the Lower Limits 22
To Set and Test the Upper Limits 23
Verify Hoist Address 23
Examine the System 23
ii Prodigy FlyPipe Studio Installation Guide

Introduction 1
Introduction
Welcome to the Prodigy FlyPipe Studio Installation Guide. This document provides details on
how to install, test and manually operate a FlyPipe Studio hoist.
Document Conventions
This document uses the following conventions to draw your attention to important information.
Note: Notes are helpful hints and information that is supplemental to the main text.
CAUTION: A Caution statement indicates situations where there may be
undefined or unwanted consequences of an action, potential for data loss or
an equipment problem.
WARNING: A Warning statement indicates situations where damage may
occur, people may be harmed, or there are serious or dangerous
consequences of an action
WARNING: RISK OF ELECTRIC SHOCK! This warning statement indicates
situations where there is a risk of electric shock.
All ETC documents are available for free download from our website: etcconnect.com.
Please email comments about this manual to: [e-mail].

2 Prodigy FlyPipe Studio Installation Guide
Help from ETC Technical Services
If you are having difficulties and your problem is not addressed by this document, try the ETC
support website at support.etcconnect.com or the main ETC website at etcconnect.com. If none
of these resources are sufficient, contact ETC Technical Services directly at one of the offices
identified below. Emergency service is available from all ETC offices outside of normal business
hours.
When calling for help, take these steps first:
•
Prepare a detailed description of the problem
•
Go near the equipment for troubleshooting
•
Find your notification number if you have called in previously
Please have the following information handy:
•
Product model and serial number (located on motor box)
•
Other components in your system (Foundation, QuickTouch, etc.)
Americas United Kingdom
ETC, Inc. ETC Ltd
Technical Services Department Technical Services Department
3031 Pleasant View Road 26-28 Victoria Industrial Estate
Middleton, WI 53562 Victoria Road,
800-775-4382 (USA, toll-free) London W3 6UU England
[phone] [phone]
[e-mail] [e-mail]
Asia Germany
ETCAsia ETC GmbH
Technical Services Department Technical Services Department
Room 1801, 18/F Ohmstrasse 3
Tower 1, Phase 1 Enterprise Square 83607 Holzkirchen, Germany
9 Sheung Yuet Road [phone]
Kowloon Bay, Kowloon, Hong Kong [e-mail]
[phone]
[e-mail]
France
ETC France
Zone Urbaparc -
Bâtiment E
6 Boulevard de la Libération
Saint-Denis, 93200
[phone]
[e-mail]

Overview 3
Chapter 1
Overview
The Overview chapter provides safety information as well as various hoist specifications.
Safety and Warnings
Only ETC Rigging trained personnel are authorized to install and configure FlyPipe Studio hoists
and any related equipment. Read this entire installation manual before installing equipment.
Please note the following safety notices before use:
WARNING: ETC Rigging systems must be installed under the supervision of
a person trained and certified in ETC Rigging Installation. If you are not an
ETC Rigging trained technician, do not attempt installation of this
equipment unless you are under the immediate supervision of an ETC
Rigging Certified Installer.
WARNING: Improper operation may cause serious injury or death.
AVERTISSEMENT : Un fonctionnement incorrect peut provoquer des
blessures graves, voire mortelles.
WARNING: Disconnect power before servicing this equipment.
AVERTISSEMENT : Déconnectez l'alimentation avant d'effectuer
l'entretien de cet équipement.
WARNING: ETC Prodigy hoists and QuickTouch and Foundation control
equipment should not be operated by a user until installation and
configuration have been completed by an ETC Rigging trained and certified
installer. Only ETC Rigging trained and certified installers are authorized to
operate equipment during the installation and configuration process.
WARNING: ETC Prodigy hoists and QuickTouch and Foundation control
equipment are designed for the raising and lowering of loads within the
approved hoist capacity only. This equipment is not designed to lift or
automate personnel and such use is strictly prohibited.
WARNING: ETC Prodigy hoists must only be used to move a maximum load
equal to or less than the capacity of your specific hoist. Overloading the
hoist may result in damage to the system or serious injury.

4 Prodigy FlyPipe Studio Installation Guide
AVERTISSEMENT : Les porteuse de Prodigy doivent uniquement être
utilisés pour déplacer une charge maximale équivalente ou inférieure à sa
capacité nominale. Une surcharge de l'appareil peut entraîner
l'endommagement du système et d'autres biens, des blessures graves, voire
la mort.
Working Load Limit (WLL)
The Working Load Limit (WLL) of any hoist is the maximum load capacity that a user may apply
to a hoist or a hoist system.
All Prodigy hoists have a Working Load Limit. This is identified on the product label on the side
of the motor box. All Prodigy FlyPipe Studio hoists have a Working Load Limit of 136 kg (300 lb).
Prodigy Working Load Limits include a design-safety factor.
WARNING: NEVERexceed the Working Load Limit for any hoist.
Hoist Specifications
The FlyPipe Studio is a self-climbing hoist made up of a control housing, motor, drum, extrusion,
SafeStop devices, and TwinLine pairs with TwinLine Clamps. The hoist extrusion provides strut
channel on the underside of the hoist body from which you can easily hang fixtures, curtains, or
other equipment.
CAUTION: Using channel hardware with springs can cause severe damage to
Prodigy FlyPipe Studio. ETC recommends using channel nuts without springs.
1.78 m (5 ft 10 in)
3.36 m (11 ft)
299 mm
(11.8 in)
540 mm
(21.3 in)
Electrical Specifications
•
FlyPipe Studio 120/208 Volt, 3-phase, 3-wire + ground, 60 Hz, 2.4 A, Motor 0.5HP
•
FlyPipe Studio 277/480 Volt, 3-phase, 3-wire + ground, 60 Hz, 1.6 A, Motor 0.5HP
•
Power and data control cables plug into motor box
Interface with Building
•
Strut channel (i.e. Unistrut® - provided by others) attaches directly to the building
structure
•
Each pair of lift lines (TwinLine) terminate to an adjustable tension beam clamp (TwinLine
clamp), which attaches to the strut channel

Overview 5
Lifting Specifications
•
Motor lifting capacity of 136 kg (300 lb)
•
Up to 7 m (23 ft) of vertical travel
•
Hoist is a zero fleet angle self-climber
•
The hoist contains two pairs of lift lines, with spacing between at 1.78 m (5 ft 10 in)
Control and Feedback
•
FlyPipe hoists can be controlled using QuickTouch or Foundation control systems
•
Roller lever limit switches provide mechanical upper and lower travel and overtravel limits
•
Incremental position encoder provides configurable soft travel limit control
•
Hoists trigger automatic shutdown in the event of overload or overcurrent conditions
•
SafeStop System provides secondary fall arrest at each lifting point
Hoist Local Controls
You can find the hoist local controls on the front of the motor box. These controls should be used
for initial operation and testing during installation.
The hoist ships with a cover over the local controls. To access the controls, loosen but do not
remove the three screws securing the cover and then slide the cover to the right.
•
Address dials: Used
to set individual
addresses for each
hoist
•
Indicator LEDs:
Provide general
information for the
hoist
•
Status LEDs: Provides
status when a specific
travel limit has been
reached
•
Override buttons:
Allows you to move
the hoist off of travel
limits that have been
reached
•
Control switch:
Activates manual
hoist movement

6 Prodigy FlyPipe Studio Installation Guide
Chapter 2
Initial Hoist Installation
The following sections provide instructions on how to begin the installation of the Prodigy
FlyPipe Studio hoist.
•
Tools Needed on page 6
•
Prepare the Installation Location on page 6
•
Unpack the Hoist on page 7
•
Attach TwinLine Clamps on page 7
Tools Needed
•
Snips or a knife (for unpacking)
•
Phillips screwdriver #1 and #2 (various uses)
•
3/8 in hex key (for attaching TwinLine clamp to strut channel)
•
17 mm socket wrench (for fine trim adjustment of TwinLine clamp)
•
Small tool (screwdriver or hex key) with shaft diameter no greater than 5 mm (0.2 in) and
length at least 30 mm (1.2 in). (Necessary only if SafeStop device has tripped)
•
Stands or sawhorses (for resting the hoist on when terminating TwinLines to the drum)
•
Nicopress tool with J groove
Prepare the Installation Location
Before you assemble and hang your hoist, you need to identify the install location and attach
strut channel, such as Unistrut, to the building structure.
•
Attachment points where TwinLine clamps terminate to strut channel must be spaced
1.78 m (5 ft 10 in) on center
•
The attachment point for the motor end TwinLine clamp must be at least
1.25 m (4ft 1 in)from the nearest wall to allow for proper clearance
•
The attachment point for the non-motor end TwinLine clamp must be at least
0.79 m (2 ft 7 in) from the nearest wall to allow for proper clearance
636 mm (25 in)
946 mm (37 in)
0.79 m
(2ft 7 in)
minimum
1.25 m
(4 ft 1 in)
minimum
Note: If your attachment points are not spaced according to the requirements above,
contact your ETC Project Manager or Technical Services. For contact information, see
Help from ETC Technical Services on page 2.

Initial Hoist Installation 7
Unpack the Hoist
When you open the box, your hoist is lying on its side. There is also a smaller box inside the
large box that includes the TwinLine wire rope, TwinLine clamps, SafeStop brakes, and stop
sleeves for terminating the wire rope to the drum.One end of the wire rope is pre-terminated to
the TwinLine clamp and the other end is loose, with the excess spooled inside cardboard. You
can use the box to rotate the hoist so it is standing upright on the foam blocks that were used as
packing material.
CAUTION: While unpacking hoist assembly, it is important to keep the
TwinLine wire ropes free of debris. The use of damaged or dirty wire ropes can
interfere with proper hoist function.
Once the hoist is unpacked, rest it on top of stands or saw horses so that it is up off the ground.
This provides the space you'll need when terminating the TwinLine lift lines to the drum.
Attach TwinLine Clamps
Once you have positioned your hoist, you must run the TwinLine and TwinLine clamps up to the
strut channel. To secure the clamps to your strut channel, perform the following steps. If you are
installing helix cable management, you should hang the cable assembly before attaching the
TwinLine clamp for the second set of lift lines that run through the cable assembly. For
instructions on hanging the cable assembly, refer to Hang Helix from Upper Attachment Points
on page 10 .
Note: The hoist must rest in a position that will allow for the entire intended travel
distance of wire rope plus 41 cm (16 in) minimum dead hang to be run up when
attaching the TwinLine clamps.
CAUTION: Before attaching the clamp to the strut channel, ensure the
following:
- The TwinLines are not twisted at any point in the run
- The cable equalizer plate is perpendicular to the clamp body
1. Run the TwinLine and TwinLine clamp up to the strut channel attached to the building
structure.
2. Rotate the channel nut so the long sides are parallel with the run of strut channel. This
ensures that the nut can be inserted into the channel.

8 Prodigy FlyPipe Studio Installation Guide
3. Insert the nut into the strut channel.
Equalizer plate
perpendicular
to clamp body
Tighten socket
cap screw
4. Using a 3/8 in hex key, tighten the socket cap screw so the channel nut rotates 90 degrees
against the walls of the strut channel and until the nut is snug against the bottom of the
strut channel. The recommended torque range for this is 68–88 Nm (50–65 ft-lb).

Cable Management 9
Chapter 3
Cable Management
Depending on your installation, you might be using standard swag cable management or ETC
designed helix cable management.
Swag Cable Management
Basic management of your power and data cables can be done using cable cradles. If you use a
cable swag for your FlyPipe Studio hoist, it is recommended that you use a split mesh rod closing
grip strain relief solution, such as ETC part number HW6971, at the swag hook position.
Install Helix Cable Management
There are two variants of the helix cable management system depending on if you are providing
power and data only to the hoist (one set of cables) or if you are also providing power and data
to a connector strip hung from the hoist (two sets of cables). The steps for installation are the
same for both variants.
When installing helix cable management, there are three components you need to consider:
•
Cable assembly: This assembly consists of the power and data cables wound around a
series of ribs which span between two lengths of nylon webbing. This assembly ships in a
smaller box that is separate from the hoist. The top of the cable assembly (to be run up)
has a male Twist-Lock connector for power and the bottom (nearest the hoist) has a
female Twist-Lock connector.
•
TwinLine and TwinLine clamp: The TwinLine associated with the second section of the
hoist (second from the motor) runs through the center of the helix. After you've installed
the TwinLine Clamp and cable assembly, you must thread the pair of TwinLine lift lines
through the grommets in the middle of each cable assembly rib.
•
Platter: The platter and the supporting brackets ship in the same box as the cable
assembly. Attach the platter to the FlyPipe Studio directly above the SafeStop device
furthest from the motor. This provides a resting place for the cable and ribs to coil as you
raise the hoist.
CAUTION: As you work with the TwinLine and TwinLine clamp throughout
this procedure, ensure that the TwinLine is not twisted at any point in the run.
Since the TwinLine runs through the middle of the helix cable management
system it can be more difficult to identify.
Unpack and Prepare
Perform the following before hanging the cable assembly.
1. Remove the cable assembly from the packaging.
2. Remove the metal rods from the cardboard triangles into which the ribs are set.
3. Remove the cardboard triangles by rotating them 180 degrees and then pulling them out.

10 Prodigy FlyPipe Studio Installation Guide
Remove metal rods
Hang Helix from Upper Attachment Points
To begin installing helix cable management, run it up to your attachment points and secure it
with the nylon webbing.
Note: If the strut channel is installed without clearance above it (i.e. attached directly
to the upper steel), create a looping point for the nylon webbing. For example, attach a
forged eye bolt to the underside of the strut channel using a strut nut and square
washer.
Mark on webbing rests approximately at
the top of the loop
Buckle
Topmost rib
Buckle Threading Diagram
1. Thread the buckles onto the nylon
webbing straps that extend beyond the
topmost rib. This step is represented by
the black dashed line in the buckle
diagram.
2. Run the cable assembly up to the
attachment points, with the topmost rib
furthest from the floor.
3. Loop one of the nylon webbing straps
around an attachment point (i.e. the
strut channel to which the TwinLine
clamp will be installed).
4. Terminate the end of the loop in the
buckle. This step is represented by the
grey dashed line in the buckle diagram.
Note: There is a mark on the nylon
webbing that is 457 mm (18 In) above the topmost rib. This mark should be
approximately at the point where the webbing loops over the attachment point.
When threading the webbing through the buckle at the top of the cable management
system, it is recommended to have the weight of the cables and ribs supported from
below. This provides an amount of slack in the nylon webbing that makes it easier to
thread the buckle.
5. Repeat steps three and four for the second nylon webbing strap.
6. Cut and remove the white cable ties that hold the cable assembly together and run the
length of the cable assembly back down to the hoist.

Cable Management 11
7. Once you have installed the TwinLine clamp, you must thead the TwinLine pair of wire
ropes through the center grommet of each rib, beginning from the topmost rib and moving
downward.
Attach the Platter to the Hoist
In these steps, you’ll need to have the TwinLine clamp and cable assembly positioned above the
hoist so there is space to attach the platter.
Note: If you have not yet terminated your TwinLine pair of lift lines to the hoist drum
for the helix cable management section of the hoist, it is recommended that you do so
before attaching the platter to the hoist. If you choose to terminate the lift lines after
attaching the platter, you will need to separate the two platter halves so you can
remove and access the SafeStop device.
1. Locate the two platter pieces, brackets and hardware in the same box in which the cable
assembly shipped.
2. Take the halves of the brackets and fit them around the hoist so there is one full bracket
on each side of the SafeStop device.
3. Using a Phillips screwdriver and the hardware provided, loosely connect both bracket
sides.
4. Take the two halves of the platter and loosely connect them to the bracketed sides using
the four 6 mm screws provided.
Combine Bracket Halves Secure Halves to Brackets and Join Together
111 mm (4.37 in) 111 mm (4.37 in)
5. Adjust the position of the brackets until the
two halves of the platter are joined.
6. Secure the platter pieces together using the
two 4 mm screws provided.
7. Tighten the four loose screws securing the
bracket sides to the hoist and the four screws
securing the platter to the brackets.
Note: The brackets are positioned approximately 111 mm (4.37 in) from each side.

12 Prodigy FlyPipe Studio Installation Guide
Attach Cable Assembly to Platter
The following instructions detail how to attach the bottom of the helix cable assembly to the
platter.
Bottommost rib
Mark on webbing rests
approximately where
webbing loops through
platter
1. Thread the buckles onto the nylon webbing
straps that extend beyond the bottommost
rib.
2. Loop the nylon webbing through the slots
on the platter.
3. Terminate the ends of the loops in the
buckles.
Note: There is a mark on the nylon webbing that is 457 mm (18 In) below the
bottommost rib. This mark should be approximately at the point where the webbing
loops through the platter.

Finalize Hoist Installation 13
Chapter 4
Finalize Hoist Installation
After assembling your hoist and installing cable management, there are a couple additional
items required before you can start running the hoist. Terminating the lift lines to the drum is the
next logical step, but before you can perform this task you need to power the hoist and ensure
the wiring is oriented properly and the motor is running in the correct direction.
•
Run Power and Data on page 13
•
Emergency Stop Termination on page 14
•
Verify Proper Wiring on page 15
•
Ensure SafeStop Devices are Open on page 18
•
Terminate Lift Lines to the Drum on page 16
•
Float the Hoist on page 19
•
Level the Hoist on page 19
•
Install Slack Line Sensor Kit on page 1
Run Power and Data
Connector receptacles on motor box
Power
Data
The hoist ships with a power cable and a data cable.
The power cable has a female Twist-Lock connector
on one end, which you should connect at the motor
box on the hoist. The other end has a male Twist-Lock,
which connects to the FlyPipe Power and Control
Distribution (PCD) box.
The data cable has round nine-pin connectors attached
to each end, one of which you should connect to a
receptacle on the hoist motor box. The other end
connects to the FlyPipe Power and Control Distribution
(PCD) box.
For additional information, refer to the Prodigy and
FlyPipe PCD Electronics Installation Guide.

14 Prodigy FlyPipe Studio Installation Guide
For helix cable management, you can
use the four cable clips included in the
helix cable management box to run
power and data across the drum
section of the hoist. To attach the
clips, join the two sides around the
pipe extrusion and secure with the M6
screw provided. Run cable ties through
the slots in the clips to secure your
power and data cables to the length of
the hoist between the helix platter and
motor box.
Emergency Stop Termination
nine-pin
connector
for hoist
control
To run the hoist up off the ground and set your
commissioning travel limits, you need a completed
Emergency Stop (E-stop) circuit. This circuit is typically
completed when the control system is installed and
energized. If a control system is not installed or
operational, insert the nine-pin E-stop Termination
Bypass Plug (ETC part # 8050B7002) into the nine-pin
male connector receptacle on the top of the motor box.
This completes the circuit and allows you to temporarily
operate the hoist from the local controls.
CAUTION: Do not insert the E-stop
Termination Bypass Plug into a Power and Control Distribution (PCD) box.
Doing so could short out the control wiring.
CAUTION: Do not leave the hoist unattended when the E-stop Termination
Bypass Plug is in place. If you need to leave the hoist for any period of time,
remove the plug from the hoist.

Finalize Hoist Installation 15
Verify Proper Wiring
Verifying the wiring for the 3-phase power receptacle is important to ensure that the hoist will
properly respond to controls. If you are installing a 120/208V hoist, you can use the Prodigy
Phase Checker (ETC part number 8055A4013). For 277/480V hoists, use a standard 3-phase
checker that is rated for 480VAC, similar to the 480V phase checker you can purchase through
ETC (part# M7639).
1. Plug the Phase Checker into the 3-phase receptacle that will provide power to your hoist.
2. Look at the LEDs on the back of the phase checker.
•
If the green LED is fully illuminated, the proper wiring is confirmed
•
If the red LED is fully illuminated, have a qualified electrician swap the supply voltage
wires going into the receptacle until the phase order is correct and the green LED is
fully illuminated.
3. Once you have confirmed proper wiring, plug the hoist power and data connectors into
the FlyPipe PCD.
If neither LED is on, either one phase of the feed is not connected or a true 208V or 480V 3-
phase supply has not been used. Contact a qualified electrician to connect the proper supply.
Note: The hoist may be at the lower overtravel limit. If so, you need to press and hold
the Overtravel Override button to move the hoist.
In addition to checking phases at the PCD, you should
also verify that the hoist is moving properly by viewing
the encoder wheel within the motor box as you
momentarily operate the hoist. When moving up , the
encoder wheel should rotate in a counterclockwise
direction.
If the encoder wheel rotates in the clockwise direction,
release the control button immediately to avoid any
potential damage to the hoist. Once the hoist is
stopped, disconnect power and verify the wiring at the
3-phase receptacle. If the wiring is correct and the
encoder is still moving in the clockwise direction,
contact ETC Technical Services for assistance.

16 Prodigy FlyPipe Studio Installation Guide
Terminate Lift Lines to the Drum
Perform the following steps to terminate your lift lines to the drum of your FlyPipe Studio.
CAUTION: Before terminating each set of TwinLine lift lines to the drum,
ensure there are no twists at any point in the run.
Step 1:Move the Drum to Top Dead
Center
You will have to bump the hoist in the UP direction to move the
drum to a top dead center position for threading the lift lines.
Moving the drum this far only requires an instant of movement,
so be careful not to over-rotate the drum. The drum is at top
dead center when the two holes in the drum are visible from
the cutout where the SafeStop device was resting.
Step 2: Thread Lift Lines Through SafeStop and Drum
CAUTION: If you trip the SafeStop device while threading lift lines through,
reset the SafeStop before you continue. Continuing to thread the lift lines
when a SafeStop device is tripped can damage the wire rope. To reset the
device, see Ensure SafeStop Devices are Open on page 18.
Thread the lift lines down through the two holes on the top of the
SafeStop device and through the sheave near the bottom. Pull the lift
lines out the bottom of the device and run them through the hoist. With
the drum at top dead center, the two holes in the drum should be
visible from the cutout where the SafeStop device was resting. Thread
the lift lines through the holes and pull them through the bottom of the
hoist down to the ground.