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003-001 PowerAssist Installation 

Page 9 of 24  

Rev. 0–27APR07 

 

 

 

 

 

        

 

 

 

 

Figure 6: Hoist nomenclature 

 

 

 

2. Install the counterweight rigging hardware 

1. Install counterweight rigging per the manufacturer’s instructions. Install everything 

including counterweight for the pipe batten weight. Do not install a hand line.  

2. If you are using existing rigging, see the Project Planning section of this manual to ensure 

that the components are suitable for this application. 

Summary of Contents for PowerAssist

Page 1: ...Design Manufacture and Installation of Theatrical Equipment Worldwide 315 451 3440 Fax 315 451 1766 www jrclancy com PowerAssist Counterweight Assisted Hoist System Installation Manual ...

Page 2: ...ST TO THE BUILDING STRUCTURE 10 4 ENERGIZE THE HOIST AND VERIFY OPERATION 11 5 INSTALL THE DRIVE CABLE 12 6 ATTACH THE DRIVE CHAIN TO THE DRIVE CABLE 14 7 INSTALL THE DRIVE CHAIN INTO THE HOIST 15 8 ATTACH THE DRIVE CHAIN TO THE UNDERSIDE OF THE ARBOR 15 9 ADJUST THE COUNTERWEIGHT AND TENSION THE DRIVE CHAIN 16 10 SET THE LIMIT SWITCHES 17 11 INSTALL ARBOR WEIGHT WARNING SIGNS 17 12 CHAIN TENSION ...

Page 3: ...n application the arbor is loaded with one half of the capacity of the counterweight set not to exceed 1000 lbs In this case when the batten is loaded with 2000 lbs of equipment the load is counterweighted by 1000 lbs and the winch bears the remaining 1000 lbs See figure 1 below When the batten has no load on it the 1000 lbs weight of the arbor is supported by the winch See figure 2 below Other ar...

Page 4: ...cture Wire guides are not recommended unless they are single arbor system located far enough away from other rigging or objects to ensure safe operation even with the loose guidance that they provide Guide rail splices should be well aligned so that shoes cannot catch Guide shoes should be in good condition and able to keep the arbor from twisting Arbors The connection to the arbor must be capable...

Page 5: ...rAssist system equal pitch diameters unequal pitch diameters Figure 3 Sheave pitch diameters 2 Winch mounting conditions The building structure to which the hoist is anchored must be of sufficient strength to resist the loads at the appropriate design factors The PowerAssist exerts 1000 lbs of uplift plus dynamic forces on the structure below Consult a qualified Structural Engineer to determine if...

Page 6: ... diameter is 0 234 inches Figure 4a Chain breaking Tool A custom made stripping guide should be manufactured to strip the ends of the cables safely See Appendix B for fabrication details A sharp razor knife is all that is required to cut the cable jacket JR Clancy Recommends using Nicopress swages to terminate the drive cable The cable is 3 8 7X 19 Galvanized Utility Cable Several Nicopress swagin...

Page 7: ...RMED BY TRAINED PROFESSIONALS WARNING LOAD MAY FALL IF PARTS ARE SUBSTITUTED USE ONLY THE PARTS PROVIDED BY THE FACTORY TO ASSEMBLE THIS MACHINE WARNING MOVING PARTS CAN CRUSH OR CUT KEEP HANDS AND FEET AWAY FROM MACHINERY IN MOTION WARNING ELECTRICAL SHOCK HAZARD INSTALLATION OF THIS MACHINE REQUIRES HIGH VOLTAGE ELECTRICAL WIRING THIS WORK SHOULD BE DONE ONLY BY QUALIFIED PERSONNEL ...

Page 8: ...003 001 PowerAssist Installation Page 8 of 24 Rev 0 27APR07 1 Nomenclature The terms seen in Figure 5 and Figure 6 will be used throughout this manual Figure 5 Drive chain nomenclature ...

Page 9: ...g hardware 1 Install counterweight rigging per the manufacturer s instructions Install everything including counterweight for the pipe batten weight Do not install a hand line 2 If you are using existing rigging see the Project Planning section of this manual to ensure that the components are suitable for this application ...

Page 10: ...arbor Center the sprockets between the guide tees as seen in Figure 7 3 Align the offstage side of the offstage sprocket with the center of the arbor as seen in Figure 8 4 The PowerAssist hoist is provided with four 9 16 holes in the base for anchoring to the facility A fastener must be installed in each of these holes We recommend that each fastener have an ultimate strength of at least 8 000 lbs...

Page 11: ...e hoist and verify operation 1 Wire the hoist per the provided electrical drawings 2 Turn on the power and make sure the sprockets are rotating in the right directions for the up and down control buttons 3 Adjust the limit switches so that the machine can move in either direction for 10 feet without hitting any limits ...

Page 12: ...r Bring the terminated end of the drive cable down to the top of the arbor and Insert the Arbor Link Spacer provided with the hoist through the wire rope thimble and into the arbor top Bolt through the arbor top with a 13 UNC Grade 5 hex bolt The Arbor Link Spacer can be identified by the two grooves turned into the part at each end See figure 8 5 The on stage end of the drive cable should be left...

Page 13: ...rive cable should be cut Cut the drive cable 7 Measure back from the new end of the cable 11 inches 20 inches if using cable clips and make a new mark This is the point where the cable must be stripped back to Strip the jacket from the cable See Appendix B 8 Use a thimble and Nicopress oval sleeve to terminate the cable as shown in Figure 8A Figure 9 Connection of the drive rope to the top of the ...

Page 14: ...n figure 10 4 Inspect any chain connections within the length provided to make sure all mending links are properly installed 5 Pin the turnbuckle into the Chain End Link and fasten the cotter pin as seen in figure 8A 6 Haul the hand line down to pull the batten and the roller chain up until the batten is at high trim Add enough counterweight to the arbor to balance the system and compensate for th...

Page 15: ... merely pin the parts in place temporarily WARNING INCORRECT COUNTERWEIGHT CAN OVERLOAD HOIST OR RIGGING AND CAUSE LOAD TO FALL HOIST CAPACITY IS 1000 LB IMBALANCE DO NOT EXCEED HOIST OR RIGGING CAPACITY DO NOT ADD OR REMOVE COUNTERWEIGHT UNLESS THE ARBOR AND OR LOAD ARE SECURED 3 For new installations with empty battens preload the drive chain by adjusting the weight in the arbor to equal one hal...

Page 16: ... NOTICE THE FOLLOWING PROCEDURE IS FOR SYSTEMS WITH A BATTEN CAPACITY OF 2000 LBS OR LESS CONTACT JR CLANCY FOR OTHER INSTRUCTIONS WHEN INSTALLING SYSTEMS OF GREATER CAPACITY 1 Double check all connections to make sure the drive chain and rope are securely fastened Add or remove counterweight so that the arbor is loaded to one half the capacity of the batten and rigging but not to exceed 1000 lbs ...

Page 17: ...CURE COUNTERWEIGHT AND INSTALL WARNING SIGNS TO PREVENT USERS FROM TAMPERING WITH WEIGHTS Install the warning sign securely onto the arbor rods in such a way as to prevent the addition or removal of weight WARNING FOR SYSTEMS WITH A BATTEN CAPACITY GREATER THAN 2000 LBS REMOVAL OF WEIGHT FROM EITHER THE BATTEN OR THE ARBOR CAN RESULT IN OVEROAD OF HOIST THE SYSTEM INSTALLER MUST ATTACH SAFETY WARN...

Page 18: ...btain a copy of this document prior to operating this machinery Operating and Maintaining the PowerAssist WARNING Improper use of this equipment can result in injury or death Read the Operation manual before using this equipment Do not operate without proper training and authorization You are responsible for identifying evaluating any hazards and determining the correct operation method to be used...

Page 19: ...oint Determine what range of normal travel of load must be set normal limits to stop load at these points For each end of travel set overtravel limit first then set end of travel limit Make sure that the operator can clearly see the entire load for its entire travel or that spotters are in place to observe and clearly communicate with the operator Adjust Limit Drive the winch to the desired end of...

Page 20: ... toward limit until limit stops motion Assess stopping position measurement vs target Drive winch off limit use overtravel bypass switch to move winch off overtravel limit Refine Limit Adjustment Repeat the Adjust Limit procedure as detailed above Move cam lobe closer to switch to make switch trip sooner decrease travel distance Move cam lobe further from switch to make switch trip later increase ...

Page 21: ... stripped back and mark it on the cable 20 inches for cable clip installation or 11 1 2 inches for nicopress installation Step 2 Use a razor knife to score the cable jacket around the full circumference at this location Figure B 1 Cutter guide installation NOTICE NOTICE NOTICE NOTICE CUT THE PLASTIC JACKET ONLY IF THE AIRCRAFT CABLE IS NICKED OR OTHERWISE DAMAGED DURING TERMINATION THAT PART SHOUL...

Page 22: ...he coated cable See figure B 2 for fabrication details on cutter guide Step 4 Use a razor knife to score the cable jacket along its length between the scored mark and the end of the cable using the saw cut in the guide as a cutting edge Step 5 Remove the cutter guide Step 6 Press the center of the knife blade into the end of the cable at an angle of about 45 degrees Rotate the knife to pop the jac...

Page 23: ...003 001 PowerAssist Installation Page 23 of 24 Rev 0 27APR07 FIGURE B 2 CUTTER GUIDE ...

Page 24: ...003 001 PowerAssist Installation Page 24 of 24 Rev 0 27APR07 REVISION HISTORY Rev Date Description DRAFT 21FEB07 DRAFT RELEASE 0 27APR07 INITIAL RELEASE ...

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