WAAGNER

BIRO SYSTEMS
STAGE
SYSTEMS
STAGE CONTROL
02

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
 STAGE SYSTEMS 03

STAGE CONTROL:
CAT CONCEPTS
THE CAT CONCEPT 4 MAXIMUM AVAILABILITY 17

CAT 190 6 CAT USER INTERFACE 19

CAT 192 8 DEAD-MAN’S FUNCTIONALITY 25

OUTLET 110 9 SPECIAL FUNCTIONS AND FURTHER OPTIONS 26

CAT 120 10 THE VIRTUAL THEATRE 29

CAT 120 R 11 CAT ON TOUR 31

CONTROLGEAR / UNICORN 12 PREVENTION AND FAST ASSISTANCE 32

AXIO II 14 AND FINALLY 34

CAT 60 15 CONTACT 34

CAT 20 16

SPECIAL CONTROL PANELS 16

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.
04 STAGE SYSTEMS STAGE CONTROL
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.
 STAGE SYSTEMS 05

System design
The block diagram shows the main components of a CAT
installation. They are explained in detail on the following pages.

Internet Server rack

Router Printer UPS

CAT192 CAT 190 CAT 120 CAT 120R

Ethernet

Server A Server B
OUTLET110 OUTLET 110 OUTLET 110 BRIDGE 110
Redundant
Ethernet

CAT 60 CAT 60

UNICORN UNICORN UNICORN UNICORN

Drive Drive Drive Drive

Centrally based controlgear

The CAT system consists of the following basic components: The programming interface CAT-Control and the drive
overview CAT-View run on desks CAT 190, CAT 192,
Control desk CAT190 or CAT192
CAT 120 and CAT 120R.
Mobile desk CAT120
Wireless desk CAT120R The cable-bound desks are connected to outlets
Local and emergency control panel CAT60 OUTLET 110, which are spread over the stage area.
Special control panels and displays
The emergency control panel CAT 60 is connected directly
AXIO II axis controllers
at the drive and allows running the drive bypassing
UNICORN control cabinets or the network and servers.
centrally based controlgear
Redundant servers The CAT system can be set up fully redundant. It offers:

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

The axis controller AXIO II is responsible for all safety

related functions as well as for drive control and
supervision of movements.
06 STAGE SYSTEMS STAGE CONTROL
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.
 STAGE SYSTEMS 07

The CAT190 is delivered with a pluggable LED gooseneck Input devices

lamp. The lamp can be dimmed continuously or regulated auto- If entering text or numbers is required, the touch screen
matically according to the surrounding light. For this purpose, shows a screen keyboard. Additionally a common USB
a luminosity sensor is integrated in the desk. (or PS/2) keyboard or mouse can be connected to the desk.

Combined with the comfortable user interface, the CAT190

ensures ergonomic and fatigueless work, an important Technical data:
prerequisite for the safety sensitive stage area.
Dimensions 675 x 465 x 165 mm (W x D x H)
Screen 19 inch screen diagonal
Identification 1280 x 1024 pixels
16 millions of colours
Access control to the CAT190 (and all other desks) is Resistive touch screen
provided by means of a transponder card. Authorisation is
Weight 15 kg
distributed to different levels and can be configured individu-
ally. According to the assigned level, different people will have Control levers 4 units with integrated dead-man's buttons
access to different functions. This increases the security of the Additionally verified by inclination sensor
system, as the authorisation to execute dangerous movements Other features 4 USB ports
and access to sensitive data is clearly regulated. The card has a 1 PS/2 port
passive transponder which is read contactlessly. 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”
Usually all drives of the installation can be controlled from External dead-man’s button “Go-button”
the CAT190. If desired the access to the stage machinery can Foot switch
be restricted depending on the user level or location of the desk. Rolling stand
It is possible to specify which drives can be controlled from Gallery stand
which outlet. Dangerous, inadvertent movements can thus
be avoided in general. The installation is optimally protected
against unauthorised access. Fixed and mobile
The CAT190 with its solid, attractive plastic housing can be
installed in a fixed location and can be integrated into the
Safety
surface of a large operating console, for example at the main
Internally the CAT190 is based on standard PC technology, control station.
complemented by two independent microcontrollers.
These read the control levers and dead-man’s switches on cat desk stand
two channels, and thus are responsible for the safety relevant
The CAT190 is mobile enough to be moved around to the
functions.
most suitable place, according to the actual needs. For instance,
it can be placed onto the “CAT Desk Stand” on wheels.
Additionally the control lever data is verified by an inclinati-
The stand's height can be adjusted, thus the desk can be used
on sensor. This ensures that the drives are only operated by a
in a standing and sitting position.
properly installed desk.
08 STAGE SYSTEMS STAGE CONTROL

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.

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.
 STAGE SYSTEMS 09

OUTLET110
If the CAT192 is not in use, the lid with the second screen The desks are connected to outlets OUTLET110. Typically
inside can be closed. In this position it also protects the other several OUTLET110s are spread around the stage area.
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: Every outlet has an emergency stop button.

Dimensions Closed: 675 x 465 x 165 mm (W x D x H) It is protected laterally by means of a protecting ring.
Open: 675 x 465 x 530 mm (W x D x H) If required the OUTLET110 can also be delivered without
Screens 19 inch screen diagonal this emergency stop button.
(2 units) 1280 x 1024 pixels
16 millions of colours The OUTLET110 has a button for activation and deactivation.
Resistive touch screen If the outlet is deactivated, the desk can be plugged or un-
Weight 22.5 kg plugged without interrupting the emergency chain. Thus no
terminating plug on an unused OUTLET110 is needed.
Control levers 4 units with integrated dead-man's buttons
Additionally verified by inclination sensor
The cable used to connect the control desks is a highly flexible,
Other features 6 USB ports specially designed lightweight cable with a diameter of about
1 PS/2 port
10 mm (approx. 1.5 kg for 10 m). The connectors are lightweight,
1 VGA port
robust and reliable. Available cable lengths are 2 m, 5 m, 10 m
Illuminated emergency stop button
XLR port for LED gooseneck lamp and 20 m.
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
10 STAGE SYSTEMS STAGE CONTROL

CAT120
The CAT120 is at the operator’s disposal as the very handy Operation
mobile desk of the CAT family. The CAT120 consists of The CAT120 is connected to the same OUTLET110 outlets
a 12.1" LCD with touch screen and has two very sensitive with the same cable as the CAT190 or CAT192.
control levers with an integrated dead-man’s button.
The desk also provides two programmable push buttons
for every control lever.

The software interface on this desk is the same as on the

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.
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.

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. Technical data:
Thus, no elements that require preventive maintenance
Dimensions 420 x 303 x 67 mm (W x D x H)
or that wear out.
Screen 12.1 inch screen diagonal
The CAT120 complies with protection rating IP54. 1024 x 768 pixels
Resistive touch screen
It therefore withstands splash water from any direction.
Weight 4 kg
Access to the desk functions is provided with the same Control lever 2 units with integrated dead-man's buttons
transponder cards as for the CAT190. 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
 STAGE SYSTEMS 11

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.
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

Radio connection to the CAT120.
The BRIDGE110 is the counterpart of the wireless desk
CAT120R. 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:
Dimensions 420 x 303 x 67 mm (W x D x H)
Screen 12.1 inch screen diagonal
1024 x 768 pixels
Resistive touch screen
The effective radius of the radio link depends on the actual Weight 4 kg (without battery)
conditions of each stage. The radio technologies used guaran- Battery Li-Ion
tee an indoor range of 100 metres. In case this should not be
sufficient, roaming is possible. Then several BRIDGE110s are Autonomy 3 – 15 h (depending on battery size)
mounted in the stage area. If the signal from one BRIDGE110 Control levers 2 units with integrated dead-man's buttons
to the CAT120R gets too weak, the desk switches over Additionally verified by inclination sensor
automatically to a different BRIDGE110 with a better signal. Protection rating IP54
Other features 2 USB ports
Illuminated emergency stop button
Safety
Access control by transponder card
To achieve safe transmission of control lever information,
Accessories Radio station “BRIDGE110”
data is read by two independent micro-controllers and
Accumulator “BATTERY120”
sent separately. On the opposite side the receiving station Charger “CHARGER120”
forwards the two values to the selected axis controllers. USB keyboard and mouse
There, two independent processors of the axis controller Carrying bag
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. 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.
12 STAGE SYSTEMS STAGE CONTROL

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.
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.

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.
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 22
990 x 395 x 470 30 to 45
 STAGE SYSTEMS 13

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.

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.
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.

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.
14 STAGE SYSTEMS STAGE CONTROL

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.
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.

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.
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.

The plug-in stations provide one or several connectors Dual safety

for the cable to the mobile drive.
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.
Control of ON-SET OBJECTS
Based on the simple analogue / digital interface it is also Due to its safety related functions the AXIO II consists
possible to use the axis controller AXIO II for the control of two parts. Each drive is controlled by a positioning CPU
of on-set objects. Thus, even such drives that are only and by a supervising CPU. In addition, this dual system is based
temporarily in use can be programmed and moved with the on diversity. The processors used for the positioning CPU and
CAT system, for example when integrated in a dedicated the supervising CPU are of a different type.
stage setting. Thus, systematic errors which could affect both of the systems
can be excluded.
There are no limits to the integration of automation solutions
in a showdeck or in scenery constructions – from simple,
2 Ethernet E-Stop Coupling logic
programmable relay contacts for inputting or outputting ports (shown for digital signals)
Outputs
control signals to the configuration of speed controlled drives
Positioning
via generic control boxes. +
-
Controller CPU Feedback
type A

Digital and
analogue inputs,
incremental Dual port Watchdog E-Stop
and absolute RAM CPU
Digital
encoders
and analog
outputs
+ Supervising
- Controller CPU Feedback
type B

Input Outputs
decoupling
E-Stop
 STAGE SYSTEMS 15

CAT60
The AXIO II offers, amongst others, the following safety The CAT60 is a handy control panel used for emergency
functions: or local operation. If necessary it is connected to the drive.

Calculation and monitoring of the motion profile The CAT60 has one control lever with an integrated
Comparison between positioning CPU dead-man's button to control the speed.
and supervising CPU In addition it offers an alphanumeric display to show
Verification of position signals position and status or error message in plain text.
(absolute and incremental) All necessary drive parameters can be indicated, and it allows
Monitoring of position deviation moving ranges to be preset. Even the maximum speed can be
preset by means of function keys.
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 Even for the CAT60 the same transponder card as for every
other desk is used for access control.
The AXIO II has sufficient spare analogue and digital inputs The configurable access levels define which card is authorised
and outputs in order to process further signals. These could be to carry out specific maintenance or emergency functions.
safety signals specific to the country or contacts specific to the
installation as can often be found in lower stages for example.
Emergency use
Every drive has a connector for a CAT60. This makes it
Maintenance friendly tool possible to run the drive directly bypassing the network and
The AXIO II possesses several useful features that aid fault- all desks. Independently from the entire installation there is a
finding in case of a malfunction or routine maintenance: guaranteed emergency mode for every drive. The drive is also
put into operation for the very first time by the same means.
The state of all inputs and outputs is shown by LEDs.
The integrated LCD shows information In case of emergency, faults can be repaired directly on the
about drive state, position or error message. 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
The AXIO II is simply plugged into its holder
limit switch. Driving into emergency limit switches for testing
and can be exchanged easily.
purpose is also undertaken by means of a CAT60.
After exchanging, the AXIO II is configured
automatically – no need for time-consuming
addressing or configuring any parameters.
16 STAGE SYSTEMS STAGE CONTROL

CAT20
Local use The CAT20 is designed as a panel-mounted manual controller.
The CAT60 can also be used to run a single drive from It is basically a cut-down version of the CAT60; the control
a permanent local control desk. To do so, the CAT60 is either lever and emergency stop button have been removed (although
installed permanently or mounted by detachable means to it is possible to connect both an external control lever and an
a holder. For local use extensive functions can be used emergency stop button). The CAT20 is operated using the
as e. g. preset several moving ranges or speed preselection. integrated push buttons.
The alphanumerical display shows the position, drive state
or error message in plain text. The functionality is the
same as for the CAT60: by
means of this operating unit,
Typical applications are the control of orchestra platforms,
the drive can be moved
curtains and simple hoists on the side stage or backstage.
bypassing the network
The CAT60 is also used for the displacement of point hoists.
and all desks.
The CAT20 makes use
Technical data: of the same transponder
Dimensions 255 x 103 x 125 mm (W x D x H) card as all other desks.
Display alphanumeric The access rights of the user
determine which functions
Weight approx. 850 g are available.
Control lever 1 unit with integrated dead-man's button Alternatively an external key switch can be connected.
The CAT20 is equipped with an alphanumeric LCD, which
Other features Access control by transponder card
Illuminated emergency stop button displays status information, such as machine name, current
For mobile use or permanent installation position, state or error messages, in an easily readable form.
Accessories Connecting cable in lengths of 1, 3, 5 and 10 m
Permanent wall bracket Technical data:
“Quick out” holder 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
PANELS
If 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.
 STAGE SYSTEMS 17

maximUM AVAILABILITY
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.
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.
18 STAGE SYSTEMS STAGE CONTROL

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 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.

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.
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 Redundant servers

One network
or a part of it fails.
One desk fails.
One outlet fails.
Both networks fail.
The converter or a different part
in the cabinet fails.
One AXIO II fails.
over to the other server.
The system switches Redundant network
over to the other network.
Server, axis controllers and desks have
two network connections!
The operator can continue More than one desk
to work with a different desk.
The operator can continue More than one outlet
to work on a different outlet.
The operator can connect a CAT60 CAT60
directly to the drive and move it locally.
The operator can replace Unicorn control cabinet
the Unicorn control cabinet
with a spare cabinet.
The operator can replace (No special requirements)
the AXIO II in a matter of minutes.
Or: the second axis controller Redundant axis controllers
takes over automatically.
 STAGE SYSTEMS 19

CAT USER INTERFACE

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 groups /
drive list

The general
function buttons

The cue list

The entry area

The log message

window

The list of groups and drives consists of several well-defined Example: Changing control lever
fields. Those fields are for instance:
Group mode
Control lever
Separate acceleration and deceleration ramps 1.
Speed
Current position
End position
Load

The entry area is context sensitive and changes its 2.

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.
20 STAGE SYSTEMS STAGE CONTROL
Example: Changing speed
1.
2.
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.
6
12 m
5
4
3
10 m
 STAGE SYSTEMS 21

Multiple straight lines Dynamic effects

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.
12
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.

11 Waterfall
7 The drives move from their start to their end positions one
6 8
9 by one. Either the starts take place with a constant delay time
5 10
4 or the delay between starting two drives depends upon the
3
physical distance between them.
4m 8m 6m 10 m

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.
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.

2
5 A drive is below a defined position.
6
A drive has reached a defined speed.
4
A drive started a defined period ago.
3
A defined delay has passed.
7
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).
TEACH-IN
It is also possible to reduce the speed of a move during
The target position does not need to be entered as a
predefined sections.
number. By means of one key press, the current position can
be taught in and saved as the target position.
22 STAGE SYSTEMS STAGE CONTROL
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.
 STAGE SYSTEMS 23

CAT-VIEW Example for lower stage view

CAT-View offers an extensive graphical with wagons, elevators and revolving stages:
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 upper stage view

with different hoists and curtain draw:
24 STAGE SYSTEMS STAGE CONTROL

Every drive is depicted by means of a bar joint to a frame. Other pages of the CAT-View provide graphical information
This frame displays the drive name, position and a state text. on predefined signals, e. g. safe edges and access doors on lifting
This text describes the current state of the drive. platforms.
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 Drive load

number
Frame
Colour depends on selected
control lever; red indicates
Numerical fault condition
position display Status text
Error message
are displayed in red
Position bar
Start position Dark blue when not selected

Position bar
Light blue when drive in use, switches to green
when reaching end postion
Decoration height With a large installation that has a lot of additional emergency
End position 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.

Dead-man’s functionality
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.
STAGE SYSTEMS 25
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.
26 STAGE SYSTEMS STAGE CONTROL
Special functions and further options
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.
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.
 STAGE SYSTEMS 27

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

Profile editor editor can be saved and can be used as profile runs in the CAT
The profile editor allows you to program the three-dimensional system. By this means even quite complex movements can
movement of an object on the screen. For instance the tilting easily be controlled from the usual user interface.
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).
28 STAGE SYSTEMS STAGE CONTROL

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
3D flying mechanism
operator does not need to correct the single drive positions
A 3D flying mechanism can be built using existing point hoists. himself in order to readjust the tension of the attachments.
Any object can be attached to the point hoists and can then be There are a lot of applications in practice: erecting a wall, tilting
flown above the area that is limited by the rope drop points of a ceiling or rigging a large decoration that tends to bend.
the point hoists.
Especially when tiling a ceiling this function reduces the risk of
For this two operational modes are available: a failure caused by shifting loads and allows tighter dimensioning
Free flying, which enables the operator to fly of the load reserves within the group.
and tilt (if applicable) the object freely by means
of a special 3D joystick.
CAT40
Flying along an existing profile. This profile
By means of the CAT40 operators can control stage machinery
can be generated from scratch using the profile
with an iPhone or iPod. The iPhone or iPod is put into the
editor or it can be recorded via teach-in.
CAT40 housing, which is slightly larger than the iPhone itself.
The housing provides a rocker switch shaped control lever for
The number of degrees of freedom for the movement
speed control. The radio connection is also integrated in the
(translation and rotation) results from the number of point
CAT40 housing, which is used to transmit the safety related
hoists involved:
movement data.
Number of Covered area Flying Tilting
point hoists on stage floor (translation) (rotation) 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.
2 Line in two no
The speed can also be preselected by the operator.
dimensions
3 Triangle in three no Using a convenient holder
dimensions
the CAT40 can easily be
4 Rectangle in three no attached to a belt.
dimensions It is thus particularly useful
8 Rectangle in three in x and y for daily rigging and
dimensions direction derigging work on stage.
 STAGE SYSTEMS 29

The virtual theatre

Photo: Paul Ott

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.

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.
30 STAGE SYSTEMS STAGE CONTROL
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).
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.

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.
STAGE SYSTEMS 31
cat ON TOUR
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.
32 STAGE SYSTEMS STAGE CONTROL
Prevention and fast assistance
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.
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.

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.
STAGE SYSTEMS 33
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.
34 STAGE SYSTEMS STAGE CONTROL

And finally CONTACT

The CAT system is in its current fourth generation and is Waagner-Biro Stage Systems International
testimony to the many years of experience in the field of stage www.waagner-biro.com
engineering by Waagner-Biro Luxembourg Stage Systems S.A.,
as well as close cooperation between venue operators and
AUSTRIA
consultants.
Waagner-Biro Austria Stage Systems AG
Technical competence is the basis for a safe and reliable Leonard-Bernstein-Str. 10,
control system. 1220 Wien, Austria
T: +43 / 1 / 288 44 0
Valuable suggestions and feedback from many installations F: +43 / 1 / 288 44-7811
all over the world ensure that CAT will continue to satisfy the E: stagesystems.austria@waagner-biro.com
ever-growing demands from our clients.
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: stagesystems.luxembourg@waagner-biro.com

GERMANY
We are convinced that this good cooperation will continue Waagner-Biro Bavaria Stage Systems GmbH
in the future in order to make each and every new Am Schönbühl 12
CAT installation a little bit better 92729 Weiherhammer, Germany
and safer each time. T: +49 /9605 /92 22 0
F: +49 /9605 /92 22-50
E: stagesystems.bavaria@waagner-biro.com

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: stagesystems.uk@waagner-biro.com

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: stagesystems.spain@waagner-biro.com
 STAGE SYSTEMS 35

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: stagesystems.china@waagner-biro.com

RUSSIAN FEDERATION
Waagner-Biro St. Petersburg Stage Systems
Nevsky prospekt 30
Office 3.10
191186 Saint Petersburg, Russian Federation
T: +7 / 812 / 449 03 91
F: +7 / 812 / 449 22 73
E: stagesystems.russia@waagner-biro.com

Office Moscow
Petrovka Street 15/13
127051 Moscow, Russian Federation
T: +7 /495 / 775 70 82, -83
F: +7 /495 / 775 70 84
E: stagesystems.russia@waagner-biro.com
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COM