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WAAGNERBIRO SYSTEMS

STAGESYSTEMS

STAGE CONTROL

STAGE CONTROL: CAT CONCEPTS

150 hoists for the upper machinery and the well-proven CAT control system in the Seoul Arts Center / South Korea.

IMPRINT

Publisher: Waagner-Biro Luxembourg Stage Systems S.A., 1, rue de l’école, BP 10, 4813 Rodange, Luxembourg

Conception and layout: simplon. Advertising, 66386 St. Ingbert, Germany

Text: Waagner-Biro Luxembourg Stage Systems S.A. and simplon. Advertising

Photos: Waagner-Biro Luxembourg Stage Systems S.A., Waagner-Biro Austria Stage Systems AG

Luxembourg, 2013

02

03STAGE SYSTEMS

THE CAT CONCEPT 4

CAT190 6

CAT192 8

OUTLET110 9

CAT120 10

CAT120R 11

CONTROLGEAR / UNICORN 12

AXIO II 14

CAT60 15

CAT20 16

SPECIAL CONTROL PANELS 16

MAXIMUM AVAILABILITY 17

CAT USER INTERFACE 19

DEAD-MAN’S FUNCTIONALITY 25

SPECIAL FUNCTIONS AND FURTHER OPTIONS 26

THE VIRTUAL THEATRE 29

CAT ON TOUR 31

PREVENTION AND FAST ASSISTANCE 32

AND FINALLY 34

CONTACT 34

This document is copyright protected, and may not be reproduced, in any form, either in its entirety, or in parts, without the prior written consent of Waagner-Biro Luxembourg Stage Systems S.A.

STAGE CONTROL: CAT CONCEPTS

04 STAGE CONTROLSTAGE SYSTEMS

OPEN CURTAIN: THE CAT CONCEPT

It’s in close cooperation with theatre consultants and technical stage staff of several theatres that Waagner-Biro Luxembourg Stage Systems S.A. (formerly Guddland digital S.A.) has developed the CAT system. CAT stands for “Computer Aided Theatre” and controls upper stage as well as lower stage machinery by means of state-of-the art technology.

CAT facilitates the daily work during the setup of a new perfor-mance as well as in the course of rehearsals and shows. The user friendly and reliable control system allows synchronisation of an unlimited number of drives.

The system is based upon almost 25 years of experience in the theatre industry and is now in its fourth generation.

User interfaces and desks reveal the close contact between developers and stage staff as well as consultants. Thanks to this precious cooperation a control concept could be generated that fits perfectly with the daily work on stage.

The CAT control system complies with the strict safety standards in the theatre industry. Redundancy on all levels ensures high availability at the same time.

Since the first installation in 1989 the CAT system has been installed in over 110 venues. Since then over 8000 drives are controlled in 35 different countries and on 13 cruise ships throughout the world.

RANGE OF USE

With the CAT stage control system it is possible to move all kinds of drives: electrical and hydraulic drives of upper and lower stage machinery, for example bar and point hoists, curtains, lighting racks, platforms, stage wagons, trap elevators, tilting devices, incliners, turntables. Thereby even extraordinary special constructions do not pose any problems.

SAFETY

The CAT system was designed according to international safety directives. The certification is based upon (amongst others):

BGV C1 (GUV 6.15)

DIN 56950

DIN EN 60204-1

DIN EN 61508

DIN VDE 0160

The CAT control system is compliant to the safety standards of the 2006/42/EU machine directive and fulfils the requirements for safety integrity level 3 (SIL 3) according to DIN EN 61508/VDE 0803 as well as performance level e (PL e) according to DIN EN ISO 13849-1.

05STAGE SYSTEMS

OPEN CURTAIN: THE CAT CONCEPT

SYSTEM DESIGNThe block diagram shows the main components of a CAT installation. They are explained in detail on the following pages.

The CAT system consists of the following basic components:

Control desk CAT190 or CAT192

Mobile desk CAT120

Wireless desk CAT120R

Local and emergency control panel CAT60

Special control panels and displays

AXIO II axis controllers

UNICORN control cabinets or centrally based controlgear

Redundant servers

The servers are industrial type IBM models. They execute central tasks, for example administration of the show database, log files and access to remote maintenance. The servers do not have any safety related functions.

The axis controller AXIO II is responsible for all safety related functions as well as for drive control and supervision of movements.

The programming interface CAT-Control and the drive overview CAT-View run on desks CAT 190, CAT 192, CAT 120 and CAT 120R.

The cable-bound desks are connected to outlets OUTLET 110, which are spread over the stage area.

The emergency control panel CAT 60 is connected directly at the drive and allows running the drive bypassing the network and servers.

The CAT system can be set up fully redundant. It offers:

Redundant servers

Redundant network

Redundant control desks

Redundant axis controllers

CAT192

OUTLET110

UNICORN UNICORN UNICORN

Centrally based controlgear

UNICORN

OUTLET 110 OUTLET 110

CAT 60 CAT 60

BRIDGE 110Server A Server B

Printer UPS

Ethernet

Router

Server rackInternet

RedundantEthernet

CAT 190 CAT 120 CAT 120R

Drive Drive DriveDrive


NETwORk

All individual components of the CAT system are connected through an Ethernet network. This simple structure offers an outstanding, high transmission speed. The clear and continuous communication structure does not need any additional data compression or protocol converters. Based on this structure, Waagner-Biro Luxembourg developed its data protocol that handles the synchronisation. It works in real-time and deterministically.

Due to its impact on the availability of the entire installation, the network can be set up in a redundant way. In this case all axis controllers and desks have two separate network ports, and all network components (e. g. switches) are doubled. If any component should fail the system switches over automatically and the network remains entirely functional.

OPERATING SYSTEM

The CAT control system is based on the Linux operating system. Linux is an open-source software, which means that the source code is freely available. When choosing this operating system, independence from a specific company was an important argument, as was known safety and reliability. This is the reason why Linux has been in use for a long time in highly available data centres as well as in countless consumer devices. Within the CAT system Linux is used throughout all levels: it ensures a reliable base for application-specific software in axis controllers, desks and servers.

MODULAR DESIGN

There is no overall supervising computer. Every drive forms an autonomous unit of its own. If, for example, an axis controller fails only a single drive is affected and all other drives remain usable.

The modular construction of the CAT system makes later expansion to an existing installation straightforward. This makes it easy to modify an existing control system step by step and to also expand smaller installations year after year with new drives.

CAT190

The CAT190 control desk continues the tradition of innovative design and excellent usability. It features a 19" LCD with touch screen and four very sensitive control levers as well as an emergency stop button. For each control lever, the desk provides two programmable push buttons and a dead-man’s button that is integrated into the control lever.

The CAT190 does not need an internal hard disk. The unit starts by means of an integrated flash memory. This memory is write-protected and therefore resistant to viruses and voltage loss. The CAT190 can be turned off without prior shutdown and this does not risk any data loss.

ERGONOMICS

The CAT190 is operated via the generously dimensioned, high-contrast 19" touch screen. The high resolution of 1280 x 1024 pixels guarantees clear and easily readable letters. The touch screen buttons on the user interface are large enough to be used simply and safely with the finger. Should the need arise; the touch screen can be recalibrated by the operator to ensure optimum operating conditions.

The four control levers are each marked with a different colour and can be assigned freely. Thus, several movements can be controlled independently, if for instance the sequence of certain movements cannot be predicted exactly.

The desk design is symmetric with two control levers on each side of the screen. Thus, it is suitable for both right- and left-handed use.

07STAGE SYSTEMS

INPUT DEVICES

If entering text or numbers is required, the touch screen shows a screen keyboard. Additionally a common USB (or PS/2) keyboard or mouse can be connected to the desk.

Technical data:

Dimensions 675 x 465 x 165 mm (W x D x H)

Screen 19 inch screen diagonal 1280 x 1024 pixels 16 millions of colours Resistive touch screen

Weight 15 kg

Control levers 4 units with integrated dead-man's buttons Additionally verified by inclination sensor

Other features 4 USB ports 1 PS/2 port 1 VGA port Illuminated emergency stop button XLR port for LED gooseneck lamp Access control by transponder card

Accessories Connecting cable in lengths of 2, 5, 10 and 20 m USB keyboard and mouse LED gooseneck lamp Protecting hard cover “CAT190-Cover” Protecting covering “CAT190-Protection” External dead-man’s button “DMB” External dead-man’s button “Go-button” Foot switch Rolling stand Gallery stand

FIXED AND MOBILE

The CAT190 with its solid, attractive plastic housing can be installed in a fixed location and can be integrated into the surface of a large operating console, for example at the main control station.

CAT dESk STANd

The CAT190 is mobile enough to be moved around to the most suitable place, according to the actual needs. For instance, it can be placed onto the “CAT Desk Stand” on wheels. The stand's height can be adjusted, thus the desk can be used in a standing and sitting position.

The CAT190 is delivered with a pluggable LED gooseneck lamp. The lamp can be dimmed continuously or regulated auto-matically according to the surrounding light. For this purpose, a luminosity sensor is integrated in the desk.

Combined with the comfortable user interface, the CAT190 ensures ergonomic and fatigueless work, an important prerequisite for the safety sensitive stage area.

IDENTIFICATION

Access control to the CAT190 (and all other desks) is provided by means of a transponder card. Authorisation is distributed to different levels and can be configured individu-ally. According to the assigned level, different people will have access to different functions. This increases the security of the system, as the authorisation to execute dangerous movements and access to sensitive data is clearly regulated. The card has a passive transponder which is read contactlessly.

Usually all drives of the installation can be controlled from the CAT190. If desired the access to the stage machinery can be restricted depending on the user level or location of the desk. It is possible to specify which drives can be controlled from which outlet. Dangerous, inadvertent movements can thus be avoided in general. The installation is optimally protected against unauthorised access.

SAFETY

Internally the CAT190 is based on standard PC technology, complemented by two independent microcontrollers. These read the control levers and dead-man’s switches on two channels, and thus are responsible for the safety relevant functions.

Additionally the control lever data is verified by an inclinati-on sensor. This ensures that the drives are only operated by a properly installed desk.


Thanks to its wheels, it can be moved to any required position. The stand includes an A4 size manuscript holder on each side. Below the desk, a shelf can be pulled out onto which the key-board and mouse can be placed if needed.

CAT SLIdING GALLERY STANd

The hinged gallery stand “CAT Sliding Gallery Stand” is deployed for use on the gallery. A guiding rail is mounted along the gallery. The stand can slide along this rail. The CAT190 can be fixed to the stand with a holder. The inclination can be adjusted without any effort by means of a manually operated pneumatic cylinder. If the desk is not needed, the stand can be tilted down to an angle of 90 degrees. The desk then hides between the protecting bars on either ends of the stand.

Thanks to the well thought-out design the same CAT190 desk can be used in any of the aforementioned stands or a panel mounted inside the main control booth or simply be used on a conventional table without any mechanical modifications.

CAT192

The CAT192 offers even more operating comfort than the CAT190. As is the case for the CAT190, there is a touch screen integrated in the desk surface. There is an additional second screen in the desk lid. Two user interfaces of the CAT software can therefore be shown at the same time: the programming interface CAT-Control on one screen, and the drive overview CAT-View on the other one. It is no longer necessary to switch between the two interfaces.

09STAGE SYSTEMS

OUTLET110

The desks are connected to outlets OUTLET110. Typically several OUTLET110s are spread around the stage area.

Every outlet has an emergency stop button. It is protected laterally by means of a protecting ring. If required the OUTLET110 can also be delivered without this emergency stop button.

The OUTLET110 has a button for activation and deactivation. If the outlet is deactivated, the desk can be plugged or un-plugged without interrupting the emergency chain. Thus no terminating plug on an unused OUTLET110 is needed.

The cable used to connect the control desks is a highly flexible, specially designed lightweight cable with a diameter of about 10 mm (approx. 1.5 kg for 10 m). The connectors are lightweight, robust and reliable. Available cable lengths are 2 m, 5 m, 10 m and 20 m.

If the CAT192 is not in use, the lid with the second screen inside can be closed. In this position it also protects the other screen.

Like the CAT190 the CAT192 features four differently coloured control levers with integrated dead-man's buttons and an emergency stop button.

The CAT192 can also be used on the stand on wheels as well as on the sliding gallery stand. With its weight at 22.5 kg, it is usable as a mobile desk despite its second big screen.

Technical data:

Dimensions Closed: 675 x 465 x 165 mm (W x D x H) Open: 675 x 465 x 530 mm (W x D x H)

Screens (2 units)

19 inch screen diagonal 1280 x 1024 pixels 16 millions of colours Resistive touch screen

Weight 22.5 kg


Other features 6 USB ports 1 PS/2 port 1 VGA port Illuminated emergency stop button XLR port for LED gooseneck lamp Access control by transponder card

Accessories Connecting cable in lengths of 2, 5, 10 and 20 m USB keyboard and mouse LED gooseneck lamp Protecting hard cover “CAT190-Cover” Protecting covering “CAT190-Protection” External dead-man’s button “DMB” External dead-man’s button “Go-button” Foot switch Rolling stand Gallery stand


CAT120

The CAT120 is at the operator’s disposal as the very handy mobile desk of the CAT family. The CAT120 consists of a 12.1" LCD with touch screen and has two very sensitive control levers with an integrated dead-man’s button. The desk also provides two programmable push buttons for every control lever.

DESIGN AND TECHNIqUE

The CAT120 is built using a very sturdy plastic housing and weighs approximately 4 kg. The desk is equipped with a touch screen, which will easily withstand over 1 million button presses. The resolution of the screen is 1024 x 768 pixels.

The desk features inclination switches, which prevent the control lever data being sent unintentionally from the desk if it is e. g. lying upside down.

The rough day to day usage of a mobile control desk was a primary design concern. Consequently there are no moving mechanical parts inside the desk: no fans, no hard disks. Thus, no elements that require preventive maintenance or that wear out.

The CAT120 complies with protection rating IP54. It therefore withstands splash water from any direction.

Access to the desk functions is provided with the same transponder cards as for the CAT190.

OPERATION

The CAT120 is connected to the same OUTLET110 outlets with the same cable as the CAT190 or CAT192.

The software interface on this desk is the same as on the CAT190. The CAT120 is mainly intended for rigging and running pre-programmed movements, rather than for sophisticated programming.

For the CAT120, a protective carrying pouch with shoulder strap is available.

Technical data:


Screen 12.1 inch screen diagonal 1024 x 768 pixels Resistive touch screen

Weight 4 kg

Control lever 2 units with integrated dead-man's buttons Additionally verified by inclination sensor

Protection rating IP54

Other features 2 USB ports Illuminated emergency stop button Access control by transponder card

Accessories Connecting cable in lengths of 2, 5, 10 and 20 m USB keyboard and mouse Carrying bag

11STAGE SYSTEMS

FUNCTIONAL RANGE

The CAT120R resembles the CAT120 in every detail. This desk also has a 12.1" LCD with touch screen and two control levers with dead-man's button. Like the CAT120 the CAT120R also complies with protection rating IP54 and is protected against splashed water from any direction.

The software user interface of the CAT120R is identical to the CAT120.

The carrying bag can also be used for the CAT120R. To enable easy changing of the battery, the bag has an opening below the battery slot.

Technical data:


Screen 12.1 inch screen diagonal 1024 x 768 pixels Resistive touch screen

Weight 4 kg (without battery)

Battery Li-Ion

Autonomy 3 – 15 h (depending on battery size)


Protection rating IP54

Other features 2 USB ports Illuminated emergency stop button Access control by transponder card

Accessories Radio station “BRIDGE110” Accumulator “BATTERY120” Charger “CHARGER120” USB keyboard and mouse Carrying bag

ENERGY

The CAT120R relies on a battery as its energy source which is available in different sizes and provides wireless autonomy for 3 to 15 hours. The remaining charge can be seen on the user interface. The battery is also equipped with a small LED bar graph, allowing the user to check the remaining power of any battery without having to insert it into a CAT120R desk first.

CAT120R

The letter “R” at the end of the name makes this desk even more flexible than the CAT120. R stands for “radio controlled”, i. e. data transmission by radio. The wireless connection makes cables to the outlet unnecessary and enables unsurpassed mobility, without the trip hazard of a wired connection. The desk can be used at the precise location offering the best view of the elements to be moved.

RADIO CONNECTION

The BRIDGE110 is the counterpart of the wireless desk CAT120R.

The effective radius of the radio link depends on the actual conditions of each stage. The radio technologies used guaran-tee an indoor range of 100 metres. In case this should not be sufficient, roaming is possible. Then several BRIDGE110s are mounted in the stage area. If the signal from one BRIDGE110 to the CAT120R gets too weak, the desk switches over automatically to a different BRIDGE110 with a better signal.

SAFETY

To achieve safe transmission of control lever information, data is read by two independent micro-controllers and sent separately. On the opposite side the receiving station forwards the two values to the selected axis controllers. There, two independent processors of the axis controller compare the data packets. If there are any differences between the data or the resulting actions, both of the processors can force an emergency stop and bring the drive into a safe state.


The battery is accessible from the outside and can be changed easily in no time. While the battery is being replaced the desk is internally powered. It does not need to be switched on again after a battery change.

The batteries are charged in a dedicated charger. During the charging process the charger constantly monitors temperature, voltage and current to ensure optimum battery life.

CONTROLGEAR

UNICORN

The UNICORN concept for control cabinets is as simple as it is ingenious: every drive has its dedicated control cabinet and this is installed next to the winch itself.

ALL IN ONE

The cabinet is entirely equipped and tested at the manufacturing site. All connections to the outside are provided by plug connec-tors. This helps to reduce time during commissioning. In case of failure, a cabinet can also be replaced easily and quickly.

The following are integrated into the cabinet:

Frequency converter

Net filter

Braking resistor (mounted on the back)

Main switch

Main contactor

Brake contactors

Power supply

AXIO II axis controller

Each cabinet is independent and does not influence any other drive in the system. The cabinets can be used for most variable speed drives and range from 1.5 kW up to 45 kW.

Dimensions (H x W x D) [mm] Power [kW]850 x 290 x 370 1.5 to 22990 x 395 x 470 30 to 45

13STAGE SYSTEMS

To reduce the cabling efforts even more, a modular busbar trunking system can be used. Those busbars are installed above the UNICORN. The cable protection fuses are placed onto the busbars. The power cables are very short with a length of about 1 metre, going from the power track to the UNICORN.

CENTRALLY BASED CONTROLGEAR

Where it is not suitable or desirable to use the decentralized UNICORN control cabinets directly next to the winches, a centrally based controlgear can be installed.

This controlgear consists of standard switch cubicles containing all of the necessary electric and electronic components for several drives. It can be located in a dedicated controlgear room.

The advantages are obvious. The cabinets are so small and light-weight that they can be fitted very close to the relevant winch. The mounting is very easy. No separate control cabinet room is necessary.

COMPLETELY PLUGGABLE

The cabling between the winch and the control cabinet is very simple. All cables are connected by plugs. So all cables can be manufactured at the factory and can be tested. The installation work on site is reduced to plugging in pre-tested cables. This reduces errors on site and facilitates maintenance, as there is no need to retighten any screw terminals.

Each cabinet is only supplied with 400 V supply and Ethernet. This reduces the amount of cabling required significantly compared to the conventional central cabinet technique.


INTEGRATION OF MOBILE MACHINES

Thanks to its modular design the CAT system is suitable for the integration of mobile machines. These can be point hoist winches on wheels, but also chain hoists from a third party supplier.

The control components are located in a decentralized control cabinet next to the machine – similar to the UNICORN concept. This cabinet is connected by means of a combined cable (for power supply and network connection) to dedicated plug-in stations.

The plug-in stations provide one or several connectors for the cable to the mobile drive.

CONTROL OF ON-SET OBJECTS

Based on the simple analogue / digital interface it is also possible to use the axis controller AXIO II for the control of on-set objects. Thus, even such drives that are only temporarily in use can be programmed and moved with the CAT system, for example when integrated in a dedicated stage setting.

There are no limits to the integration of automation solutions in a showdeck or in scenery constructions – from simple, programmable relay contacts for inputting or outputting control signals to the configuration of speed controlled drives via generic control boxes.

AXIO II

The AXIO II is the axis controller of the CAT system. The modular design of the CAT installation is prepared for one axis controller per drive. Upon failure of one AXIO II, only the corresponding drive is affected. The rest of the system continues to work normally.

In special circumstances one AXIO II can be used to control more than one machine. The machines in such applications usually do not use an encoder or variable frequency drive; instead the motor might be controlled using simple reversing contactors.

DUAL SAFETY

The AXIO II performs the safety functions of the installation, such as synchronizing the drives, monitoring the motion profile or stopping in a synchronous, controlled way in case of an error.

Due to its safety related functions the AXIO II consists of two parts. Each drive is controlled by a positioning CPU and by a supervising CPU. In addition, this dual system is based on diversity. The processors used for the positioning CPU and the supervising CPU are of a different type. Thus, systematic errors which could affect both of the systems can be excluded.

Dual port RAM

Watchdog CPU

2 Ethernetports

E-Stop Coupling logic(shown for digital signals)

E-Stop

Outputs

Outputs

Feedback

Feedback

E-Stop

Digital and analogue inputs, incremental and absolute encoders Digital

and analog outputs

Input decoupling

Positioning Controller CPU

type A

Supervising Controller CPU

type B

+-

+-

15STAGE SYSTEMS

CAT60

The CAT60 is a handy control panel used for emergency or local operation. If necessary it is connected to the drive.

The CAT60 has one control lever with an integrated dead-man's button to control the speed. In addition it offers an alphanumeric display to show position and status or error message in plain text. All necessary drive parameters can be indicated, and it allows moving ranges to be preset. Even the maximum speed can be preset by means of function keys.

Even for the CAT60 the same transponder card as for every other desk is used for access control. The configurable access levels define which card is authorised to carry out specific maintenance or emergency functions.

EMERGENCY USE

Every drive has a connector for a CAT60. This makes it possible to run the drive directly bypassing the network and all desks. Independently from the entire installation there is a guaranteed emergency mode for every drive. The drive is also put into operation for the very first time by the same means.

In case of emergency, faults can be repaired directly on the drive. In a special user mode the CAT60 ignores error checks, e. g. to repair a crosswire fault or to get out of an emergency limit switch. Driving into emergency limit switches for testing purpose is also undertaken by means of a CAT60.

The AXIO II offers, amongst others, the following safety functions:

Calculation and monitoring of the motion profile

Comparison between positioning CPU and supervising CPU

Verification of position signals (absolute and incremental)

Monitoring of position deviation

Control and verification of brakes and frequency converter

Load measurement, detection of overload and underload

Crosswire switch

Slack rope detection

Emergency limit switches

Temperature monitoring of motor and braking resistor

Temperature monitoring inside the control cabinet

Brake air gap monitoring

Monitoring of safe edge sensors

Dynamic restriction of speed or travel distance

The AXIO II has sufficient spare analogue and digital inputs and outputs in order to process further signals. These could be safety signals specific to the country or contacts specific to the installation as can often be found in lower stages for example.

MAINTENANCE FRIENDLY TOOL

The AXIO II possesses several useful features that aid fault-finding in case of a malfunction or routine maintenance:

The state of all inputs and outputs is shown by LEDs.

The integrated LCD shows information about drive state, position or error message.

The AXIO II is simply plugged into its holder and can be exchanged easily.

After exchanging, the AXIO II is configured automatically – no need for time-consuming addressing or configuring any parameters.


LOCAL USE

The CAT60 can also be used to run a single drive from a permanent local control desk. To do so, the CAT60 is either installed permanently or mounted by detachable means to a holder. For local use extensive functions can be used as e. g. preset several moving ranges or speed preselection. The alphanumerical display shows the position, drive state or error message in plain text.

Typical applications are the control of orchestra platforms, curtains and simple hoists on the side stage or backstage. The CAT60 is also used for the displacement of point hoists.

Technical data:


Display alphanumeric

Weight approx. 850 g

Control lever 1 unit with integrated dead-man's button

Other features Access control by transponder card Illuminated emergency stop button For mobile use or permanent installation

Accessories Connecting cable in lengths of 1, 3, 5 and 10 m Permanent wall bracket “Quick out” holder

CAT20

The CAT20 is designed as a panel-mounted manual controller. It is basically a cut-down version of the CAT60; the control lever and emergency stop button have been removed (although it is possible to connect both an external control lever and an emergency stop button). The CAT20 is operated using the integrated push buttons.

The functionality is the same as for the CAT60: by means of this operating unit, the drive can be moved bypassing the network and all desks. The CAT20 makes use of the same transponder card as all other desks. The access rights of the user determine which functions are available.

Alternatively an external key switch can be connected. The CAT20 is equipped with an alphanumeric LCD, which displays status information, such as machine name, current position, state or error messages, in an easily readable form.

Technical data:

Dimensions 163 x 93 x 40 mm (L x W x D)

Display alphanumeric

Weight approx. 400 g

Control lever none

Other features Access control by transponder card

Accessories External illuminated emergency stop button External control lever with integrated dead-man’s button

SPECIAL CONTROL PANELSIf the standard desks do not seem suitable for a specific use, the CAT system can also handle signals from different control units. This may be, for example, a wall mounted panel with simple push buttons, or also a special local control unit with a touch screen display.

17STAGE SYSTEMS

HARD DISkS

Independently of the number of servers that are installed, each server has two hard disks. These are controlled by a RAID system. The RAID system permanently mirrors data between the two hard disks. If a hard disk should fail, this failure is dis-played and the disk can easily be exchanged for a new one.

DESkS

Intentionally, the CAT system hosts only a few different models of desks. If, for instance, for the main control desk as well as for the mobile desk on stage the CAT192 desks are used, these are 100 % interchangeable. If one of the desks fails, the other one can be used as a replacement without any constraints.

The CAT120 or CAT120R could be used to replace a CAT190. Although these desks only have two control levers, they can also handle programmed movements with more than two control levers. The user interface provides an easy means to alter existing programming, such that all the moves could still be executed.

High availability was a primary design concern for the CAT system. A single faulty component should not stop the entire system from working. Single points of failure have either been avoided entirely or have been eliminated by introducing redundancy.

Modular design and several redundancy levels prevent possible shortages:

Nearly all components are easily swapped with identical replacements.

Redundancy is available for critical system parts.

The overall result is a system with a high degree of availability without making any compromises on safety.

NETwORk

All network members of the CAT control system feature two separate network ports. Every axis controller and every desk is connected to different Ethernet switches. If any switch fails, a corresponding counterpart will take over automatically.

SERVER

Instead of one central server, a redundant server system is used. In parallel to the main server, a second server mirrors every data modification to its hard disk. In case the main server should fail, the system can be switched over to this backup server. This switchover happens automatically, but it can also be carried out manually by the operator. The system runs with full functionality on the backup server.

The entire hardware of the server exists in duplicate. This leads to far higher reliability than for example mirroring only the hard disk within the same server.

For special demands, the system can be extended to three or even four servers.

MAXIMUM AVAILABILITY


AXIS CONTROLLERS

The easiest and most cost-saving redundancy is keeping a spare axis controller AXIO II. The AXIO II was designed to be easy to maintain. It is simply inserted into its mounting base. Exchanging an AXIO II can be accomplished quickly and without any tools.

If an AXIO II is out of service, it needs only to be exchanged for a different one – without any complex addressing. The axis controller is configured automatically for the relevant drive.

Replacing an AXIO II axis controller does not require any configuration by maintenance staff. The parameters for all drives in the installation are held inside every AXIO II. Every drive is identified by means of an ID chip, which is read during boot-up of the AXIO II. So any AXIO II can replace any other one.

If the requirements for availability do not allow this fast exchange of an axis controller, a level of redundant axis controllers is possible. In this case, two entire AXIO IIs are installed. Redundant axis controllers detect for themselves if one of the axis controllers has failed. The other one can continue without any restriction.

EMERGENCY CONTROL AT THE DRIVE

The CAT60 is a last resort for any drive in the CAT system. Each drive has a local connector for the CAT60 to control the drive directly. In this case, there is no requirement for any working central component such as a desk, a server or a network.

The following table summarises the different failure scenarios, and the solutions that the CAT system has to offer. Note that many of the offered solutions do not make any compromises in the level of functionality, or safety.

What can fail? How is this failure backed up? What is needed?

One server fails. The system switches over to the other server.

Redundant servers

One network or a part of it fails.

The system switches over to the other network. Server, axis controllers and desks have two network connections!

Redundant network

One desk fails. The operator can continue to work with a different desk.

More than one desk

One outlet fails. The operator can continue to work on a different outlet.

More than one outlet

Both networks fail. The operator can connect a CAT60 directly to the drive and move it locally.

CAT60

The converter or a different part in the cabinet fails.

The operator can replace the UNICORN control cabinet with a spare cabinet.

UNICORN control cabinet

One AXIO II fails. The operator can replace the AXIO II in a matter of minutes.

(No special requirements)

Or: the second axis controller takes over automatically.

Redundant axis controllers

19STAGE SYSTEMS

The user interface consists of two displays:

The programming screen CAT-Control

The machine display screen CAT-View

CAT-CONTROL

CAT-Control enables the user to carry out all of the day-to-day tasks with ease. Whether a simple stage-wagon move or an entire pre-programmed elevator landscape, it can all be realised

at the touch of a button. Irrespective of the complexity of a move, moving a single bar hoist and recording a dead during a rehearsal is no different to moving 40 chessboard elevators during an actual show. The appearance of the CAT-Control is always consistent.

The operator can directly access all of the frequently used functions. Rather less frequently used functions are accessed through menus. The screen is divided into several parts:

The list of groups and drives consists of several well-defined fields. Those fields are for instance:

Group mode Control lever Separate acceleration and deceleration ramps Speed Current position End position Load

The entry area is context sensitive and changes its appearance according to the value to be modified. Changing a value on the screen needs two steps:

1. Touching the field to be changed.2. Entering the new value by means of the entry area.

Example: Changing control lever

1.

2.

The cue list

The log message window

The groups / drive list

The entry area

The general function buttons

CAT USER INTERFACE


Example: Changing speed

BASIC CONCEPT

1. The required drives are assembled into groups, so that several drives can be moved with one control lever.

2. Once a group is formed, one or more deads can be defined for it. A dead is the end position of a group, whereby the drives of a group are allowed to have different end positions. A group can have an unlimited number of deads.

3. The next step is the creation of cues. One or more deads form a cue. Every dead can be specified by entering speed, acceleration and many other parameters.

4. The show consists of the individual cues, which will be started successively. Each individual show can be stored in a repertory.

With this basic concept it is possible to create an entire show in a simple and consistent manner, without further knowledge about the user interface. Beyond this, CAT offers a multitude of additional functions to either facilitate daily work or to provide specific special effects for more demanding applications. Some of these functions are explained below.

SYNCHRONOUS MOVEMENTS

CAT offers different options to define the movement characteristics of the drives within a group:

ASYNCHRONOUS

In this mode all drives travel at the speed entered by the operator, and reach their target positions at different times, according to the distances travelled.

TIME SYNCHRONOUS

In this mode the drives adjust their speeds according to the distances to be travelled, such that all drives reach their target positions at the same time.

dISTANCE SYNCHRONOUS

In this mode all of the drives in a group must always travel the same distance. The relative distance between different drives remains constant. The typical application would be a heavy load that is hung on several bar hoists, which would then always be moved simultaneously.

CALCULATING TARGET POSITIONS

In particular applications, CAT offers additional functions to calculate the target positions for a group of drives.

STRAIGHT LINE

A ceiling suspended from several hoists needs to be tilted. In order to do so, the operator only enters the position of two hoists (e. g. of the first and of the last) while the system automati-cally calculates the positions of the remaining hoists.

12 m

34

56

10 m

1.

2.

21STAGE SYSTEMS

MULTIPLE STRAIGHT LINES

This effect requires the user to enter more than two predefined points. A predefined point is defined by entering a target position for one drive. For each pair of neighbouring predefined points, a straight line is calculated. The drives that lie between such a pair will have their end positions set to the intersection with the straight line.

PLANE

As well as bar hoists being lined up on a straight line, point hoists can be used to build an inclined plane. To place the drives of a group in a plane, exactly three drives from the group need to have a target position entered. CAT calculates the target positions for the remaining drives.

34

56

78

910

11

12

4 m 8 m 6 m 10 m

TEACH-IN

The target position does not need to be entered as a number. By means of one key press, the current position can be taught in and saved as the target position.

25

6

3

7

4

DYNAMIC EFFECTS

Sophisticated movements can be programmed easily by means of so called dynamic effects, for example:

FLIP

This effect allows the drives to be moved between their start and end positions repeatedly without needing to change the direction of the control lever. The operator enters the number of direction inversions.

WATERFALL

The drives move from their start to their end positions one by one. Either the starts take place with a constant delay time or the delay between starting two drives depends upon the physical distance between them.

CONDITIONS

Normally all of the drives in a group start moving to their target positions as soon as the control lever is deflected and the dead-man’s button is pressed. CAT also offers the option of attaching conditions to a move, such that the move is only started when the condition is met.

Some of the available conditions are:

A drive is above a defined position.

A drive is below a defined position.

A drive has reached a defined speed.

A drive started a defined period ago.

A defined delay has passed.

Wait for an additional dead-man’s button.

Wait for timecode (with connection to light or sound control).

Wait for an input signal from an external source (for instance from a switch contact in a scenery).

It is also possible to reduce the speed of a move during predefined sections.


RIGGING

The rigging function is provided to help the operator with daily tasks. For example:

SCENERY HEIGHT

The scenery height is used to adjust the current position of a drive to display the effective height above the stage floor. The piece can then be flown in to a minimum position of 0 m, at which point it should just be touching the stage floor.

LOAd SUPERVISION

When a piece is rigged, its actual weight is recorded, and used to customise the overload and underload protection settings. For a light piece the overload limit could then be set to a fraction of the actual capacity of a bar hoist, offering additional safety.

TOP LIMIT

If a piece must not exceed a certain height, then a top limit can be set by the user.

MAXIMUM SPEEd

If required, the maximum speed of a rigged piece can be set.

RIGGING PLAN

The rigging plan shows an overview of the rigged pieces in a fly tower, as well as the unrigged pieces belonging to the current show.

FURTHER FUNCTIONS

CAT offers many additional practical functions, some of which go beyond the scope of this document. The following is a selection of the functions which have proven particularly useful:

REPLACE dRIVE

In case of the failure of one drive it is often possible to use an adjacent drive for the same task. The decoration is mounted to the adjacent drive, and in the programming the defective drive can be replaced with the new one.

TRIM POSITION

In a distance synchronous group the trim command is used to adjust the relative distances between the drives.

SETBACk CUE

This very useful function enables the operator to build a new cue, which moves all the groups to the position they would have been at, had the entire show been run from the beginning, up to the selected cue.

USER LIMITS

Should the need arise the operator can restrict the travel of any drive with custom upper and lower limits.

IMPORT/ EXPORT SHOWS

The programmed shows are saved in the so-called repertory. This repertory is saved in the database on the server. As external storage media, USB sticks can be connected to one of the USB ports on the desk.

PRINT

The operator can print out lists of shows, cues and groups in different formats.

NOTEPAd

As soon as an operator logs in at a desk, CAT will first open a notepad on the screen. Here the operator finds notes left by his colleagues concerning current events and particularities. He can also enter notes himself at any time.

23STAGE SYSTEMS

CAT-VIEw

CAT-View offers an extensive graphical representation of all drives in the installation. It indicates, amongst others:

Drive name

Current position

Drive state

Control lever assignment

Error message

Bar for current position

Marks for start position

Marks for end position

Scenery height

Load

Example for lower stage view with wagons, elevators and revolving stages:

Example for upper stage view with different hoists and curtain draw:


Other pages of the CAT-View provide graphical information on predefined signals, e. g. safe edges and access doors on lifting platforms.

With a large installation that has a lot of additional emergency stop buttons, the CAT-View has other pages showing the status of the emergency stop buttons.

A separate page for the CAT-View, the system screen, provides detailed information on the system state. This includes e. g. details on the emergency chain, central circuit breakers and the status of the server. Thanks to coloured markings a defective function can be recognised at a glance.

Every drive is depicted by means of a bar joint to a frame. This frame displays the drive name, position and a state text. This text describes the current state of the drive. Besides the numerical value, the drive bar offers a quick orien-tation concerning the drive’s position. In an additional frame the current load or (on a stage elevator) the current locking state can be displayed.

Details of a drive on CAT-View:

Drive loadDrive number

Numerical position display

Start position

End position

FrameColour depends on selected control lever; red indicates fault condition

Position barDark blue when not selected

Position barLight blue when drive in use, switches to green when reaching end postion

Decoration height

Status textError message are displayed in red

25STAGE SYSTEMS

It is generally necessary for a push button to be pressed as acknowledgement as long as a drive is moving. This so-called dead-man’s button is by default integrated in the control lever. For special use cases there are optional equipment and functions.

GO-BUTTON

The Go-button is connected to the CAT190 or CAT192. If the button is pushed, all currently selected drives run with their programmed speeds to their target positions.

To take over direct control of the drives that are programmed on a specific control lever, the operator can easily push the dead-man’s button on this control lever. The Go-button will then be ignored by these drives; they follow the deflection of the control lever as if the Go-button was not present. At the same time all other drives continue their programmed moves as long as the Go-button is pressed.

FOOT SwITCH

The foot switch has the same functionality as the Go-button. The foot switch can also be connected to the CAT190 or CAT192 and acts as a dead-man’s button for all selected drives.

EXTERNAL DEAD-MAN’S BUTTON

If the decorations to be moved cannot be seen clearly from the desk, an additional dead-man’s button (DMB) can be connected to the CAT190 or CAT192 desk. In this case, the control lever on the desk is only effective if the additional dead-man’s button is pressed at the same time. By means of the user interface the operator can program for which movements the additional dead-man’s button is needed.

For safety reasons the external dead-man’s button cannot be combined with the functionality of the Go-button or of the foot switch in the same CAT system.

PUSH BUTTONS BESIDE THE CONTROL LEVER

There are two programmable push buttons affiliated with each control lever. Just as with the control lever, these are read and processed dually. Therefore the buttons can also be used for safety related functions, for instance as an alternative to the dead-man’s button in the control lever. There are a variety of functions that can be attributed to the buttons – from start /stop-commands to locking and unlocking elevators.

dEAd-MAN’S FUNCTIONALITY


TIMECODE INTERFACE

The CAT system can be connected to a central show computer, the lighting desk or the sound desk. Two interfaces are available: MIDI or SMPTE LTC. A MIDI bridge receives an external timecode, which is forwarded to the CAT system. It is then possible to execute cues synchronously with the light or sound system. For safety reasons such applications still make use of the dead-man’s button on the CAT desk.

It is also possible to simulate the timecode inside the CAT system. This is useful when the operator wishes to check the details of a performance, without having to rely on other parties to provide the right timecode. The timecode can then be set arbitrarily, played back or be paused.

PROFILE RUN

By means of the profile run you can record movement profiles and replay them in a cue. Thus you can precisely repeat complex motions and combined movements. In contrast to the dead not only the end position is saved, but also how the drives run to this end position. During the recording of a profile the positions of the drives are determined and saved permanently. Exactly these positions over time can be replayed later on.

As long as the dead-man’s button is pushed, the positions of the drives are recorded and saved in the profile. The recording can be interrupted and continued at will. This is particularly helpful if the completed profile run is composed of different movement fragments. The movements can be recorded bit by bit. Whenever the dead-man’s button is pushed, the recording runs. When the dead-man’s button is not pushed, the next part of the movement can be planned or even programmed without any hurry.

Also during the recording all tools for programming are available (end position, ramps, speed etc.). Thus not only a freely operated move can be saved in the profile, but also several precise movements can be strung together.

SIMULATION

It is always possible to program a show without really moving the drives to the programmed target positions. The CAT system also offers a simulation mode (offline mode). In this mode for example shows can be programmed and tested in the office.

For this purpose, in the easiest case a computer that runs the CAT software is used. But it is also possible to use the same desks as used on the stage. In this case, a dedicated OUTLET110 is installed in the place which is used for work preparation by the theatre. There, any of the existing desks can be connected in order to use them in simulation mode. From this OUTLET110, no drives can be moved. The drives only move on the screen, but not onstage.

Shows that were programmed in simulation mode (offline mode) can be transferred to any other desk and are then available for running the real drives.

Simulation and offline programming using the same hardware as for running the show, is more sensible than the use of exter-nal computers for this purpose. The operator can run through the entire course of movements with the original hardware.

LASER MEASURING SYSTEM

FOR DISPLACEABLE POINT HOISTS

In order for a group of point hoists to form a three-dimensional plane, their exact drop points need to be known. The coordinates of these drop points can be measured along the x and y axis using a laser distance meter.

CAT offers an interface to such laser distance metres, which is then attached to the last pulley to measure the distance to the defined reference axis.

SPECIAL FUNCTIONS ANd FURTHER OPTIONS

27STAGE SYSTEMS

PROFILE EDITOR

The profile editor allows you to program the three-dimensional movement of an object on the screen. For instance the tilting of a ceiling or the moving curve of a flying mechanism can be created graphically by this means. For this purpose some standard configurations are available: from a simple up-down-movement with one bar hoist to a freely flying object that is attached to 8 point hoists. Movements with up to 6 degrees of freedom can be programmed (translation and rotation into any direction).

The operator indicates graphically the moving curve for the object by setting position marks. For this purpose the profile editor shows two side views, a top view and an isometric view whose viewing angle can be changed dynamically. The speed is also programmed graphically – in the display of speed over time (speed curve). Of course all curves can also be modified later on.

Several profiles can be treated at the same time. Like this it is possible for instance to adjust the flying moves of several actors towards each other.

The profile editor translates the demands for the moving object into the actual machine movements. Even during the graphical programming the physical limits of the machines involved are monitored to ensure they are not exceeded, for instance regarding the available rope length, the load allowed or the maximum acceleration.

All of these drive parameters can be set up in the profile editor, as can the characteristics of the moving object (fixing points, weight, degrees of freedom etc.). The graphic display in the profile editor allows real-time simulation. The stage and the moving object can also be imported as a graphic model, thus enabling additional collision detection.

The movements that have been programmed in the profile editor can be saved and can be used as profile runs in the CAT system. By this means even quite complex movements can easily be controlled from the usual user interface.


AUTOMATED LOAD EqUALIzING

When a decoration is hanging on several drives, the load is often distributed unevenly over the individual drives. This might even lead to an overload on one single drive, although the total load is not too high for all of the drives involved.

The CAT system provides a very helpful function to distribute the load evenly over the drives in a group. The drives control the load distribution within the group during the movement and adapt permanently their relative positions to the neighbour drives, so that the load is distributed evenly over all drives. This helps to prevent undesirable overload failures, and the operator does not need to correct the single drive positions himself in order to readjust the tension of the attachments. There are a lot of applications in practice: erecting a wall, tilting a ceiling or rigging a large decoration that tends to bend.

Especially when tiling a ceiling this function reduces the risk of a failure caused by shifting loads and allows tighter dimensioning of the load reserves within the group.

CAT40

By means of the CAT40 operators can control stage machinery with an iPhone or iPod. The iPhone or iPod is put into the CAT40 housing, which is slightly larger than the iPhone itself. The housing provides a rocker switch shaped control lever for speed control. The radio connection is also integrated in the CAT40 housing, which is used to transmit the safety related movement data.

On the CAT40, the operator can select a single drive or a group of drives. These can be operated in free run or to a target position. The speed can also be preselected by the operator.

Using a convenient holder the CAT40 can easily be attached to a belt. It is thus particularly useful for daily rigging and derigging work on stage.

3D FLYING MECHANISM

A 3D flying mechanism can be built using existing point hoists. Any object can be attached to the point hoists and can then be flown above the area that is limited by the rope drop points of the point hoists.

For this two operational modes are available:

Free flying, which enables the operator to fly and tilt (if applicable) the object freely by means of a special 3D joystick.

Flying along an existing profile. This profile can be generated from scratch using the profile editor or it can be recorded via teach-in.

The number of degrees of freedom for the movement (translation and rotation) results from the number of point hoists involved:

Number of point hoists

Covered area on stage floor

Flying (translation)

Tilting (rotation)

2 Line in two dimensions

no

3 Triangle in three dimensions

no

4 Rectangle in three dimensions

no

8 Rectangle in three dimensions

in x and y direction

29STAGE SYSTEMS

VIRTUAL THEATRE (3D VIEw)

The Virtual Theatre provides dynamic 3D views of the auditorium, stage and decorations on a designated screen. The programmed stage movements can be simulated with moving decoration in real-time and in a photo-realistic view.

BASE: THE 3D MODEL

The 3D model of the theatre is created based on stipulated 2D drawings or 3D CAD models. Photographs taken from the auditorium and from the stage are integrated into the model, thus enhancing the precision of the given model.

All machines controlled by the CAT system are integrated in the Virtual Theatre. In simulation mode counterweight hoists can also be displayed.

Phot

o: P

aul O

tt

THE VIRTUAL THEATRE


CONNECTION TO LIGHT CONTROLS

The Virtual Theatre can also be connected to light control desks. A library of lighting fixtures is provided. The lighting fixtures are placed like decorations in the Virtual Theatre.

Over the Art-Net protocol the Virtual Theatre receives DMX data sent by the light control desk and displays the corresponding lighting effect. This facilitates one common simulation for the coordination of stage machinery and lighting in one system.

REAL TIME OPERATION AND 3D SIMULATION

The programmed cues can be displayed in real-time. For this, the Virtual Theatre is connected to the CAT system so that it reflects the state of the drives on stage.

The Virtual Theatre can also be used in simulation mode for show preparation. Instead of moving the real drives, the show is simulated on screen. Necessary changes and refinements during the show run can be done made and rehearsed immediately.

DECORATIONS

3D models of decorations can be imported into the view. This helps to check their appearance during the movement in a very early phase and without rehearsing on stage or building a set design model. Time-wasting and personnel-intensive work on stage can be considerably reduced.

A standard library of decorations is available, e. g. tables, chairs, platforms, curtains of different colours. The decorations can be scaled in all three dimensions. Additionally, there is an option to import user defined decorations.

VIEwPOINTS

Several viewpoints are pre-programmed as e. g. a view from proscenium, stage left, stage right, middle of auditorium. The user can add additional viewpoints on their own.

The user can easily switch between the pre-programmed and the self-defined viewpoints. The position of the viewpoint can be changed dynamically with the mouse, with a 3D joystick or can be entered as X, Y, Z coordinates.

A seat selection utility allows the viewpoint to be positioned exactly in a given seat, thus allowing them to see precisely what a spectator in this seat would see (sight lines).

31STAGE SYSTEMS

This procedure is highly useful and helps to save valuable time during planning and preparation. Modifications on the decora-tion and in the show run can be done quickly and easily within the Virtual Theatre. There is no need for set models, technical rehearsals and build-up / cut-down works on stage – or at least they can be reduced to a minimum.

The show that has been simulated in this way can be taken over to the stage as is and can be run with real drives from one of the CAT desks.

MOBILE SOLUTIONS

The operational range of the CAT system is not restricted to fixed installations in opera houses, concert halls and theatres. Thanks to the modular design CAT is also suitable for going on tour with mobile drives.

On a mobile CAT system the central components, for example instance servers and network distributors, are mounted in a 19" rack and protected in a flight case on wheels. Depending on the requirements the mobile system can be assembled with the same requirements for high availability as a fixed installation: with redundant servers, redundant network and UPS. Even a connection for remote maintenance is provided.

The mobile CAT system has two outlets, which the CAT192, CAT190 and CAT120 desks can be connected to. The power for the control system is provided by a standard 230 V AC supply.

The drives (for instance chain hoists) are connected to distribution boxes. Every distribution box (PowerDistribution) provides connectors for up to 4 drives, each of which has its own fuse protection. The distribution box is powered by a common 32 A 400 V CEE connector. The connection to the CAT system is provided with a light cable which transfers the hardware emergency stop signal and network data.

CAT ON TOUR


ERROR REPORT

If the CAT system happens to detect an internal error, it sends by email a bug report to Waagner-Biro Luxembourg. The sending of a report can also be initiated by the operator. The operator can enter their own text, for instance describing the issue from their point of view or ask a question. Incoming reports are sent to the responsible staff members and are stored in a database (Request Tracker).

The Request Tracker is used to administrate error reports, suggestions and messages from the operators as well as planned tasks for every installation. Simple search functions help for example to recall the works to be carried out during the next maintenance session for an installation.

Every single item in the request tracker is assigned to a respon-sible staff member. Any colleague can add comments inter-actively. The processing of the items is documented, and the items are marked as “closed” only when the error was resolved or when the work was carried out.

Over the intervening years a well documented knowledge database has grown up that assembles the experience of various colleagues. In case of a fault, a search for a similar incident can rapidly provide a proposal for solution with precise instructions.

SYSTEM CHECkS

The CAT system features various supervision functions and automatic routines to discover errors at an early stage. These check amongst others:

System load

Remaining hard disk space

Free memory capacity

Server runtime

Correct mirroring of data on the backup server

The results of these tests are forwarded daily to Waagner-Biro Luxembourg and are administrated in an overview. Unusual values are marked in colour, and the responsible staff members get a message. The overview offers a variety of inter-active functions by means of which further investigation can be initiated.

The CAT system is characterised by a high degree of reliability and availability. To ensure constant performance throughout the life of the CAT system, two things are of prime importance: recognising problems at an early stage and fast assistance when a problem has occurred.

REMOTE MAINTENANCE

If required, Waagner-Biro Luxembourg can connect to any CAT system. The system can be analysed at any time from the company’s site in Luxembourg to provide a quick response in the case of an error. Thanks to the continuous network concept it is possible to have a look into the axis controllers, frequency converters and desks by remote maintenance. By this means, the operator on-site can be helped quickly and effectively in a tricky situation.

Hardware and software can be checked through remote maintenance. If needed, files can be transferred and software can even be updated. Data transfer is encoded through a VPN (Virtual Private Network) and additionally protected against unauthorized access by means of a firewall and password.

LOG FILES

All operations of the CAT system are logged with their corres-ponding time stamp in several log files. Their main purpose is maintenance and early problem detection. In case of an error, they allow all details leading up to the error to be tracked. In case of irresponsible usage of the system, the log files can be used as a “flight recorder” to reconstruct all incidents.

The log files are mirrored automatically from the CAT installation to a company server at Waagner-Biro Luxembourg. Thus, even error messages dating from a long time ago are available for later analysis.

PREVENTION ANd FAST ASSISTANCE

33STAGE SYSTEMS

This permanent control enables potential problems to be detected in advance. Action can be taken even before there is a real failure.

TELEMETRY

The CAT system is equipped with a powerful diagnostic tool. The so-called telemetry offers detailed diagnostics of the entire installation with a graphical user interface. Drive data such as speed, position and acceleration are recorded permanently. Not only physical quantities can be measured. Even calculated quantities such as set speed or position deviation can be recorded, even if they are not accessible to common measurement tools. Internal data within the axis controller, e. g. variable contents or the used processor time, can also be evaluated.

The recorded data are displayed graphically. Several different channels can be switched on and off independently from each other. Curves can be overlaid and scaled in order to compare them. For example, different drives can be compared regarding their power consumption. Or a drive's emergency braking distance can be compared to its distance from a previous brake test.

All recorded data can be put into relation with each other in various combinations: Which drive had what malfunction? Did the malfunction occur mainly at a special time of day? By means of various functions, statistical data can be gained, for instance: What distances did the single drives move? How often were the brakes activated? What power was consumed over the past four weeks?

By default, all important parameters are recorded, including position, following-error, speed and load. This allows later analysis on every movement in connection with user entries and / or error messages.

ANNUAL MAINTENANCE

Apart from checks by remote maintenance, the CAT system should be serviced on site once a year by a Waagner-Biro Luxembourg technician. The maintenance works include:

Testing the entire installation (drives, desks, outlets, ...)

Cleaning or replacement of soiled parts (fans, filters, dissipaters, ...)

Exchange or repair of defective components

Software updates (if necessary)

STANDBY SERVICE

On request, Waagner-Biro Luxembourg can arrange for an optional standby service. Depending on the customer’s needs this standby service can be provided by telephone or by a permanent staff member on site.


wAAGNER-BIRO STAGE SYSTEMS INTERNATIONAL

www.waagner-biro.com

AUSTRIA

Waagner-Biro Austria Stage Systems AGLeonard-Bernstein-Str. 10, 1220 Wien, Austria T: +43 / 1 / 288 44 0 F: +43 / 1 / 288 44-7811 E: [email protected]

LUXEMBOURG

Waagner-Biro Luxembourg Stage Systems S.A.1, rue de l’école 4813 Rodange, Luxembourg T: +352 / 50 35 21 F: +352 / 50 35 24 E: [email protected]

GERMANY

Waagner-Biro Bavaria Stage Systems GmbHAm Schönbühl 12 92729 Weiherhammer, Germany T: +49 / 9605 / 92 22 0 F: +49 / 9605 / 92 22-50 E: [email protected]

UNITED kINGDOM

Waagner-Biro UK Stage Systems Ltd.c/o P.O. Box 8, Johnson Street Barnsley, South Yorkshire S75 2BY, United Kingdom T: +44 / 1226 / 205761 E: [email protected]

SPAIN

Waagner-Biro Spain Stage Systems S.A.c/Santisima Trinidad 30 28010 Madrid, Spain T: +34 / 91 / 447 57 29 F: +34 / 91 / 446 18 67 E: [email protected]

ANd FINALLY CONTACT

The CAT system is in its current fourth generation and is testimony to the many years of experience in the field of stage engineering by Waagner-Biro Luxembourg Stage Systems S.A., as well as close cooperation between venue operators and consultants.

Technical competence is the basis for a safe and reliable control system.

Valuable suggestions and feedback from many installations all over the world ensure that CAT will continue to satisfy the ever-growing demands from our clients.

We are convinced that this good cooperation will continue in the future in order to make each and every new CAT installation a little bit better and safer each time.

PR CHINA

Waagner-Biro (Shanghai) Stage Systems Co. Ltd.Rm 401, No. 28 Xuanhua Road Changning District 200050 Shanghai, PR China T: +86 / 21 / 32505513 F: +86 / 21 / 32505517 E: [email protected]

RUSSIAN FEDERATION

Waagner-Biro St. Petersburg Stage SystemsNevsky prospekt 30 Office 3.10 191186 Saint Petersburg, Russian Federation T: +7 / 812 / 449 03 91 F: +7 / 812 / 449 22 73 E: [email protected]

Office Moscow Petrovka Street 15/13 127051 Moscow, Russian Federation T: +7 /495 / 775 70 82, -83 F: +7 /495 / 775 70 84 E: [email protected]

35STAGE SYSTEMS

VISITWAAGNER-BIRO.

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