Download 1.01 PowerLift™ Winch: A. General The winch shall be of a compact

1.01 PowerLift™ Winch:
A. General
1. The winch shall be of a compact design with all required components
integrated into its structure. It shall incorporate a structural backbone with
adjustable steel mounting clips to facilitate horizontal or vertical mounting.
The drum shall move along its axis as it rotates in such a manner that there is
a zero degree fleet angle between the cable takeoff points on the drum and
the head block sheaves incorporated in the winch.
2. All components shall be designed to properly support the required loads.
3. Characteristics: The winch shall have the following characteristics:
Product Code
018-P0220F
Speed (fpm)
20
Capacity
(lb)
2000
Lift Lines
7
Travel
70’
018-P1208V
018-P1220V
0 - 120
0 - 120
775
2000
7
7
70’
70’
018-P1809V
018-P1813V
018-P1820V
0 - 180
0 - 180
0 - 180
875
1275
2000
7
7
7
70’
70’
70’
B. Gearmotor and Brake:
1. The motor, primary brake and gearbox shall be an integrated unit. For
enhanced reliability a continuous shaft shall carry the brake, motor armature
and the first stage pinion gear without the use of couplings.
2. Motors shall be totally enclosed fan cooled (TEFC) per NEMA MG1.
3. The gear reducer shall employ helical gearing. The gear case shall be cast
iron for protection against shock damage. The output shaft shall have triple
lip oil seals to prevent leaks. The gear motor shall have a minimum service
factor of 1.0.
4. Brakes shall be spring applied, direct acting, electrically released, and
equipped with a manual release. The brake shall be an electro-magnetic unit
with a minimum retarding torque equal to 200% of motor full load torque. The
brake shall be released by energizing the coil simultaneously with the motor
winding to provide fail-safe breaking in case of power failure.
C. Drum & Sheaves
1. The drum shall be helically grooved to accept a single layer of cable
accommodating the entire travel distance plus three dead wraps per cable.
2. Cables shall enter the drum through key slots and be retained by a
Nicopress™ stop sleeve.
3. Chase rollers shall be provided to keep lift lines in their grooves.
4. The pitch diameter of all drums and sheaves shall meet or exceed the wire
rope manufacturer’s minimum recommended D/d ratio. Wire rope groove
profiles shall meet the recommendations of the Wire Rope Technical Board.
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5.
6.
Sheaves shall be molded in Nylatron GS®, and shall have a 5” minimum pitch
diameter with a groove for 3/16”. galvanized aircraft cable. The groove shall be
deeper than the cable diameter for protection. The sheave shall be equipped
with a 12 mm diameter machined steel shaft and two sealed, precision ball
bearings.
Loft blocks external to the winch shall have side plates of 12-gauge steel
which shall fully enclose the sheave. Idlers shall be provided for ongoing lift
lines. To minimize cable wear each cable shave have its own groove. Idlers
with more than one wire rope in a groove are specifically forbidden.
D. Load Brake:
1. A Weston type load control brake shall be located on the low speed output
shaft of the gearbox or be directly fixed to the winch drum. This brake shall
be self applied in a manner that prevents runaways and shock loads.
E. Limit Switches
1. A total of four mechanically driven limit switches shall be provided for normal
end of travel and over travel indication. Switches shall be positively driven.
2. Limit switches shall be set to match actual site conditions. Reliance on
encoders for end of travel safety functions is not permitted.
3. Switches shall be wired in a normally closed, or other circuit, that stops
motion in the even of a failure in the circuit.
F. Motor Controllers:
1. For fire and electrical safety, motor controllers shall conform to the NEC, be
built in accordance with UL Standard 508, and be “touch safe” per IEC 204-1
“Protection against direct contact” rules.
2. The controller shall be sized to match the winch motor horsepower. Overload
and overcurrent protection shall conform to UL and NEC requirements,
including accessibility.
3. Controllers shall be wired so that operation of the normal end of travel limit
switches shall only allow movement away from the limit switch.
4. The E-stop and overtravel limit switches shall be part of a circuit which is
separate from and redundant to the normal end of travel limit switches.
Operation of an E-stop or overtravel limit switch shall directly disconnect
power from the winch(es), applies the primary brake(s), and will not allow
further movement in either direction. A spring return toggle switch shall be
housed inside the controller cabinet to allow override of the overtravel limits
for resetting purposes.
5. Variable speed controllers shall be solid state flux vector controllers designed
for hoisting duty. The controller shall incorporate closed loop feedback using
a solid state position encoder mounted on the motor shaft to identify the
speed and position of motor shaft in order to provide the greatest accuracy
and performance. Each controller shall incorporate a microprocessor to
provide direct control of torque and shaft position. The controller shall
provide an essentially infinite speed range, including the ability to produce full
torque at zero speed. The use of open loop drives is prohibited.
6. Controllers shall provide under voltage, over voltage, instantaneous over
current, overload, and phase loss protection.
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G. Control Station:
1. Control stations shall be wall mounted NEMA 1 enclosures, containing a hold
to operate (dead man) Up and Down pushbuttons for each winch. A key
operated On / Off switch shall be provided.
2. A red, mushroom head emergency stop pushbutton shall be provided, which
will disconnect power to the winch through a fail safe circuit.
3. Panel components (pushbuttons, key switches, switches, indicators, E-stop
switches, and the like) shall be industrial grade.
H. Installation supervision and commissioning of the motorized rigging system shall
be performed by a factory authorized and trained technician.
1.02 SceneControl™
A. The SceneControl system shall be specifically designed for the control of
theatrical rigging equipment. The control system shall be built from standard, off
the shelf industrial grade Programmable Logic Controller (PLC) components,
selected for long term, reliable operation under the conditions and environment at
the site. “Home” computers are not acceptable for overhead motion control.
B. Operations:
1. Manual Control: The system shall allow the selection of one to six motors for
control, through the use of “AND” and “THRU” functions. Selected motors
may be controlled directly using manual “GO UP” and “GO DOWN” controls,
or they may be directed to target positions selected numerically with the on
screen keyboard.
2. Cue Control: Motor speeds and target positions can be composed, stored,
modified, and recalled in the form of cues. Each cue shall control up to six
motors, each with an individual direction, speed, and target position.
3. Groups:
Several motors may be grouped together for synchronized
operation. When motors are placed in a group, the system shall only permit
operation of the group as a whole, and shall not permit the individual
operation of any of the motors forming the group (except for trimming
functions). During group movement, the system shall track the positions of all
of the motors in the group and shall make any required correction to keep the
group synchronized. Should one or more motors fail to stay within the
window of tolerance for grouped operation or reach its end of travel limit, the
system shall automatically bring the entire group to a halt.
4. The system shall include password-protected access, with separate levels for
user, supervisor, and setup functions.
C. Operator Interface:
1. An industrial grade video touch screen shall be provided as the primary
operator interface. A graphic user interface shall be provided for ease of
operation. Displays shall include a winch controller allowing the selection of
motors for direct control; cue creation and editing; a display of the current
position and target position of each winch or group. A winch status display
shall allow the user to review the status of each winch including limit switch
actuation, running hours, and fault indications.
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2. Two cue controllers shall be provided, each with a compact industrial joystick
and pushbuttons. Joysticks shall provide velocity adjustment of movements
in progress. All direct control of motion shall be through joysticks and
illuminated pushbuttons. The touch screen shall not be used to initiate or
stop motion to prevent inadvertent initiation of movement.
3. “Deadman” operation is required, so that the operator must be at the console
and pressing a button for motion to continue. Systems that allow motion to
occur with no operator presence are prohibited.
4. a mushroom head “EMERGENCY STOP” button and a “ON/OFF” key
operated switch shall be provided on the control console.
5. The console shall be height adjustable.
D. All hardware components shall be industrial grade equipment designed for use in
a typical theatre environment. All control modules shall be standard, off the shelf
products of Mitsubishi Electric, Siemens, Allen Bradley, or other approved PLC
manufacturer. These modules shall be widely available on an international basis
to ensure ease of replacement and maintenance.
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