ETC Prodigy FlyPipe Studio User manual

Prodigy FlyPipe
Installation Guide
Part Number: 8006M2100 Rev: G
Released: 2021-06

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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
Interface with Building 4
Physical Dimensions 4
Electrical Specifications 5
Lifting Specifications 5
Control and Feedback 5
Hoist Local Controls 5
Begin Hoist Installation 6
Tools Needed 6
Prepare the Installation Location 6
Unpack the Hoist 7
Install Coupler in Span Sections 7
Assemble the Hoist Sections 7
Attach TwinLine Clamps 9
Begin Cable Management Installation 10
Swag Cable Management 10
Helix Cable Management 10
Unpack and Prepare 10
Hang Helix from Upper Attachment Points 11

Run and Verify Hoist Electrics and Data 12
Run Power and Data 12
Emergency Stop Termination 13
Verify Proper Wiring 14
Verify Hoist Is Not On Overtravel Limit 14
Verify Hoist Motor Orientation 14
Terminate Lift Lines to the Drum 15
Step 1:Verify the Drum is At Top Dead Center 15
Step 2: Thread Lift Lines Through SafeStop and Drum 15
Step 3: Attach Stop Sleeves to Lift Lines 16
Step 4: Finalize Lift Line Termination 17
Finalize Hoist and Cable Management Installation18
Attach the Platter to the Hoist 19
Attach Cable Assembly to Platter 20
Ensure SafeStop Devices are Open 21
Float the Hoist 22
Level the Hoist and Test Movement 22
Test Hoist Movement 22
Install Slack Line Sensor Kit 22
Adjust Timing of the Hoist 23
Test and Adjust 24
Adjust SafeStop Device Position for Fleet Angle 24
Configure and Test Hoist Operation 26
Verify Hoist Function 26
Travel Limits 27
Set and Test your Limits 28
ii Prodigy FlyPipe Installation Guide

To Set and Test the Lower Limits 28
To Set and Test the Upper Limits 29
Verify Hoist Address 29
Examine the System 30
Table of Contents iii

1 Prodigy FlyPipe Installation Guide
Introduction
Welcome to the Prodigy FlyPipe Installation Guide. This document provides details on how to
install, test, and manually operate a FlyPipe 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].

Introduction 2
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]

3 Prodigy FlyPipe Installation Guide
Chapter 1
Overview
The Overview chapter provides safety information as well as various hoist specifications.
Safety and Warnings
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 is complete
and the system has been commissioned 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.

Overview 4
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 hoists have a Working Load Limit of 225 kg (500 lb).
Prodigy Working Load Limits include a design-safety factor.
WARNING: NEVERexceed the Working Load Limit for any hoist.
Hoist Specifications
The FlyPipe hoist is made up of three different types of sections. Each hoist consists of Drive and
End sections and up to four Span sections. The self-climbing hoist provides strut channel on the
underside of the hoist body from which you can hang fixtures, curtains, or other equipment.
CAUTION: Using channel hardware with springs can cause severe damage to
Prodigy FlyPipe. Only use channel nuts without springs.
Drive section Span section End section
Motor box
TwinLine
Limit switches
TwinLine clamp
SafeStop device
Splice plate
and cover
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
Physical Dimensions
•
Drive Section: 3.4 m (11 ft)
•
Span Section: 3.05 m (10 ft)
•
End Section: 2.13 m (7 ft)
•
Motor Box:
-
1HP Motor: 527 mm (21 in) H x 357 mm (14 in) W x 357 mm (14 in) L
-
1.5HP Motor: 686 mm (27 in) H x 457 mm (18 in) W x 357 mm (14 in) L

5 Prodigy FlyPipe Installation Guide
Electrical Specifications
•
FlyPipe 120/208 V, three-phase, three-wire + ground power, 60 Hz, 3.8 A, Motor 1 HP
•
FlyPipe 277/480 V, three-phase, three-wire + ground power, 60 Hz, 1.8 A, Motor 1 HP
•
FlyPipe-XL 120/208 V, three-phase, three-wire + ground power, 60 Hz, 4.2 A,
Motor1.5HP
•
FlyPipe-XL 277/480 V, three-phase, three-wire + ground power, 60 Hz, 2.1 A,
Motor1.5HP
•
Power and data control cables plug into Drive section
Lifting Specifications
•
Motor lifting capacity of 225 kg (500 lb)
•
Up to 15 m (50 ft) of vertical travel
•
Hoist is a zero fleet angle self-climber
•
Each section of the hoist contains one pair of lift lines, with spacing between each pair at
3.05 m (10 ft)
•
At minimum, there must be 11 kg (25 lb) of load on each TwinLine pair of lift lines to
avoid a slack line condition
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

Begin Hoist Installation 6
Chapter 2
Begin Hoist Installation
The following sections provide instructions on how to begin the installation of the Prodigy
FlyPipe hoist.
•
Tools Needed on page 6
•
Prepare the Installation Location on page 6
•
Unpack the Hoist on page 7
•
Install Coupler in Span Sections on page 7
•
Assemble the Hoist Sections on page 7
•
Attach TwinLine Clamps on page 9
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)
•
2.5 mm hex key (for assembling the hoist)
•
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
3.05 m (10 ft) on center
•
The attachment point for the Drive section TwinLine clamp must at least
1.68 m (5 ft 6 in) from the nearest wall to allow access to the motor box
•
The attachment point for the End section TwinLine clamp must be at least
1.2 m (4 ft 0 in) from the nearest wall to allow clearance for the End section
1.68 m
(5 ft 6 in)
minimum
1.2 m
(4 ft 0 in)
minimum
3.05 m
(10 ft)
1.37 m
(4 ft 6 in)
1.07 m
(3 ft 6 in)
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.

7 Prodigy FlyPipe Installation Guide
Unpack the Hoist
Your hoist is shipped in large boxes. The Drive and End sections are packaged in the same large
box and each Span section is packaged in a separate large box.
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.
You will find tape securing cotter pins through the hoist extrusion. Do not remove the tape or
cotter pins until after the hoist sections are attached.
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.
Install Coupler in Span Sections
There is a coupler already installed in the
drive section of the hoist but you need to
install the coupler for each span section. The
coupler for each span section is included in
the box along with the TwinLine clamps. To
install, remove two clevis pins and insert into
the end of the span section where the splice
cover is located. This end should always be
placed furthest from the motor during
assembly. Secure by inserting the two clevis
pins through the extrusion and coupler.
Assemble the Hoist Sections
Once the couplers are installed, rest the sections on top of stands or saw horses so that it is up
off the ground. It is easier to position each section on stands individually rather than try to move
it after it has been fully assembled and you need the hoist on stands when terminating the
TwinLine lift lines to the drum.
Remove
clevis pins
The recommended order in which to
attach the sections is Drive to Span to
End. If necessary, you can assemble
them in any order. To attach any of
the hoist sections, perform the
following steps:
1. Remove the clevis pins from
the exposed section of the
drum shaft. To remove the
clevis pin, depress the plunger
and pull on the other end.
2. Shift the two sections together so they are fully joined.

Begin Hoist Installation 8
Shift sections together
3. Reinsert the clevis pins into the retaining holes to secure the sections.
Reinsert
clevis pins
4. Position the splice plates so they align with the four screw holes in the tube extrusion.
Using a Phillips screwdriver, secure each splice plate with the four M5 screws. (The splice
plates and screws are in a bag that is packaged in the TwinLine clamp box.)
Remove cotter pin
Position splice plates
5. Remove the tape and cotter pin from the hoist section with the splice cover.
6. Slide the splice cover so it is centered on the two hoist sections.
Slide splice cover
7. Using a 2.5 mm hex key, secure the splice cover on each side of the tube with the
provided set screws.

9 Prodigy FlyPipe Installation Guide
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 11 .
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.
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.
3. Insert the nut into the strut channel.
Tighten socket
cap screw
4. Using a 10 mm (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).
Note: TwinLine clamps can be installed perpendicular or parallel to the strut channel.
However, the clamps must always be installed perpendicular to the batten or body of
the hoist.

Begin Cable Management Installation 10
Chapter 3
Begin Cable Management Installation
Depending on your installation, you might be using standard swag cable management or ETC
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.
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. Consider the following components of helix cable management:
•
Cable assembly: This assembly consists of the power and data cables wound around a
series of ribs which span two lengths of nylon webbing. This ships in a smaller box,
separate from the hoist. The top of the assembly (to be run up) has a Twist-Lock plug
connector for power and the bottom (nearest the hoist) has a Twist-Lock socket connector.
There is a length of cable spooled and secured with a white cable tie on both ends for
running to the appropriate cable termination points.
•
TwinLine and TwinLine clamp: The TwinLine associated with the second SafeStop device
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 and are attached to the FlyPipe above the SafeStop device second 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
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.
Remove metal rods

11 Prodigy FlyPipe Installation Guide
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.
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 gray
dashed line in the buckle
diagram.
5. Repeat steps three and four for
the second nylon webbing
strap.
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.
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.
6. Cut and remove the white cable ties that hold the spooled ends of the cable assembly
together and run the length of the cable assembly back down to the hoist.
7. Once you have installed the TwinLine clamp, you must thread the TwinLine pair of wire
ropes through the center grommet of each rib, beginning from the topmost rib and moving
downward.

Run and Verify Hoist Electrics and Data 12
Chapter 4
Run and Verify Hoist Electrics and Data
After the initial cable management installation, you have access to your hoist electric and data
cables. It is important to run them to the appropriate connectors on the hoist and verify that the
hoist is running properly before you terminate the lift lines to the drum.
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 Twist-Lock receptacle
connector on one end, which you should connect at
the motor box on the hoist. The other end has a
Twist-Lock plug connector, 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 PCD box.
Note: Each time you power the hoist on, a 10 second delay will occur before
movement can begin. During this time, the Power status LED will blink.
For additional information, refer to the Prodigy and FlyPipe PCD Electronics Installation Guide .

13 Prodigy FlyPipe 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 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 connector 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.

Run and Verify Hoist Electrics and Data 14
Verify Proper Wiring
Verifying the wiring for the three-phase power receptacle is important to ensure that the hoist
will properly respond to controls. If you are installing a 120/208 V hoist, you can use the Prodigy
Phase Checker (ETC part number 8055A4013). For 277/480 V hoists, use a standard three-phase
checker that is rated for 480 VAC, similar to the 480 V phase checker you can purchase through
ETC (part# M7639).
1. Plug the Phase Checker into the three-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 208 V or 480 V
three-phase supply has not been used. Contact a qualified electrician to connect the proper
supply.
Verify Hoist Is Not On Overtravel Limit
If the hoist has shipped with the drum positioned on the overtravel limit, the hoist will not move
when you first attempt movement. If this is the situation, you need to press and hold the
OVERTRAVELoverride button for 10 seconds (the Power LEDwill blink) to allow for movement
off the overtravel limit.
Verify Hoist Motor Orientation
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
three-phase receptacle. If the wiring is correct
and the encoder is still moving in the clockwise
direction, contact ETC Technical Services for
assistance.

15 Prodigy FlyPipe Installation Guide
Chapter 5
Terminate Lift Lines to the Drum
Perform the following steps to terminate your lift lines to the drum of your FlyPipe.
CAUTION: Before terminating each set of TwinLine lift lines to the drum,
ensure there are no twists at any point in the run and that the lines are
plumb.
Step 1:Verify the Drum is At Top Dead Center
The drum is at top dead center when the two holes in the drum are visible from the cutouts
where the SafeStop devices rest. This is the position of the drum when it is shipped and is the
position required to thread the lift lines through the drum.
Step 2: Thread Lift Lines Through SafeStop and Drum
1. Thread the lift lines down through the two holes on the top of the SafeStop
device and through the sheave near the bottom.
2. 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.