d&b audiotechnik Z5820 Rigging Manual
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d&b audiotechnik Z5820 Rigging Manual

d&b audiotechnik Z5820 Rigging Manual

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  • Page 1 Rigging manual 1.1 en...

  • Page 2: General Information

    Notes on document version Version 1.1: Initial edition. General information CCL Rigging manual Version: 1.1 en, 04/2025, D2782.EN .01 Copyright © 2025 by d&b audiotechnik GmbH & Co. KG; all rights reserved. Keep this document with the product or in a safe place so that it is available for future reference.

  • Page 3: Table Of Contents

    1.6  Operational safety..............7 11.1  Mechanical setup..............61 CCL Rigging components........... 8 11.2  Wiring..................61 2.1  Z5820.000/Z5820.001 CCL Flying frame set....... 8 12 Hoisting, aiming and securing the array....62 2.2  Z5820 CCL Flying frame components........8 12.1  Hoisting the array..............62 2.2.1 ...

  • Page 4: Safety

    1  Safety Safety   1.1  Intended use The CCL rigging components must only be used in conjunction with d&b CCL loudspeakers as described in this manual. 1.1.1  d&b ArrayCalc For both safety and acoustic reasons, d&b line arrays must be designed using the d&b ArrayCalc simulation software. The software is available as a native stand-alone application for both Microsoft Windows and Mac OS X operating systems and can be downloaded at www.dbaudio.com.

  • Page 5: General Safety

    1.3  Components and weights/Load capacity Load capacity NOTICE! Z5820 CCL Flying frame The Z5820 CCL Flying frame including Beam extension is designed to support a total system weight of 500 kg (1100 lb) - SWL including all rigging components. System components and weights...

  • Page 6: Secondary Safety

    Safety   1.4  Secondary safety General   d&b rigging systems All d&b rigging systems are inherently safe up to their uppermost d&b rigging systems offer dedicated safety connection points for suspension point. According to the "German regulation DGUV a secondary safety device and are delivered with a matching Information 215-313", hence they do not require a secondary safety chain.

  • Page 7: Wind Loads

    Safety   1.5  Wind loads WARNING! Potential risk of personal injury and material damage! Flying loudspeakers overhead at wind forces higher than 6 bft (22-27 knots, 39-49 km/h, 25-31 mph) is not recommended. If the wind force exceeds 8 bft (34-40 knots, 62-74 km/h, 39-46 mph): ▪ Make sure that no person remains in the vicinity of the array. ▪...

  • Page 8: Ccl Rigging Components

    Please verify the shipment for completeness and proper condition of the items. Z5820.000 CCL Flying frame set (15.5 kg/34.2 lb) - consisting ▪ [1] Z5820 CCL Flying frame (12.5 kg/27.6 lb) with Beam extension [1.1] (3 kg/6.6 lb), optionally including (Z5820.001 CCL Flying frame set AS): Z5711 ArraySight sender unit [5] (Þ...
  • Page 9 Z5831 Safety chain set (please refer to Þ Chapter 1.4 “Secondary safety” on page 6). Z5711 (AS option) With the Z5820.001 Flying frame set AS, the flying frame is equipped with a calibrated and adjusted d&b Z5711 ArraySight sender unit (laser inclinometer). An appropriate shielded ArraySight sender unit CAT5e 1:1 cable, 30 m (100 ft) is also provided (K6006.200.00) to allow read out either...

  • Page 10: Flying Frame Center Beam And Beam Extension

    CCL Rigging components   Z5820 CCL Flying frame dimensions in mm [inch] 2.2.1  Flying frame center beam and Beam extension The center beam of the Flying frame provides a hole grid consisting of up to 32 holes with a one (1) hole detent to allow either Dual or Single pick point operation.

  • Page 11: Rear Link Of The Flying Frame

    CCL Rigging components   2.2.2  Rear link of the Flying frame Rear link position By factory default, the Rear link is attached to the flying frame for the deployment of CCL-TOP cabinets (TOP POSITION). To deploy CCL-SUB cabinets and for mixed groundstack setups with the Flying frame as ground support, the Beam extension needs to be attached to the frame and the Rear link position has to be changed to the dedicated hole position (SUB POSITION) on the...
  • Page 12 CCL Rigging components   3. Release the ring cotter [C] of the fixing bolt [B] and remove the fixing bolt. 4. Take off the Rear link. 5. Attach the Rear link to the dedicated hole position (SUB POSITION) on the Beam extension. 6.

  • Page 13: Z5824 Ccl Pullback Frame

    CCL Rigging components   2.3  Z5824 CCL Pullback frame The CCL Pullback frame is intended as a pullback device attached to the last cabinet of a pure CCL -TOP (CCL8/CCL12) array. It can also be used as ground support or adapter frame in pure CCL-TOP or mixed CCL ground stack setups.

  • Page 14: Z5831 Safety Chain Set 1.4 T

    CCL Rigging components   2.4  Z5831 Safety chain set 1.4 t The Z5831 Safety chain set 1.4 t is supplied with the Flying frame and is used as a secondary safety device, if applicable. Please also refer to Þ Chapter 1.4 “Secondary safety” on page 6. Specification Lifting chain (DIN EN 818) 1-leg, 6 mm...

  • Page 15: Ring Cotters

    CCL Rigging components   Functionality (Quick lock mechanism) The quick lock mechanism applies to all types of Locking pins. Proceed as follows: 1. Press the button to Release the locking mechanism ( [R]). 2. Remove the Locking pin through the respective link or socket. 3.

  • Page 16: Suspension Of The Flying Frame

    CCL Rigging components   2.8  Suspension of the Flying frame The suspension of the CCL Flying frame is performed using the center beam hole grid. This allows for either Single or Dual pick point operation. For this purpose, the corresponding enclosed CCL Load adapters are used.

  • Page 17: Ccl Load Adapter

    CCL Rigging components   2.8.4  CCL Load adapter With the CCL Flying frame two CCL Load adapter and the additional CCL Load adapter Rota clamp are provided. Attaching the CCL Load adapter 1. On the frame, release the corresponding Locking pin that holds the Load adapter in its park position and take off the adapter.

  • Page 18: Cabinet Rigging Mechanism

    CCL Rigging components   2.9  Cabinet rigging mechanism The cabinets are mechanically connected to the Flying frame and subsequent loudspeakers using the Front links attached to both sides of the cabinet front and the central Splay/Rear link at the rear of the cabinet. All necessary rigging components are mounted to the cabinet and slide out when needed.

  • Page 19: Splay/Rear Link Mechanism

    CCL Rigging components   2.9.2  Splay/Rear link mechanism TOP cabinets On CCL-TOP cabinets, release the respective Locking pins and fold out the Splay link. Note: For CCL-TOP speakers of the first series batch, the Splay link is cut from solid steel [A] (high pressure water jet cut), while for the following series batches, the Splay link will be a forged variant [B].

  • Page 20: Ccl Touring Cart/ Wheel Board

    CCL Rigging components   2.10  CCL Touring cart/ Wheel board Intended use The d&b CCL Touring carts are an integrated part of the CCL rigging system. They serve for transport purposes as well as for setup, requiring less space on-site. In addition, either the CCL Flying frame and its Beam extension or the CCL Pullback frame or the CCL Mounting frame top can alternatively be stored in the cart.
  • Page 21 CCL Rigging components   Loading the cart Note: All cabinets have to be set to 0° splay. 1. Extend the Front links and release the Splay link of the first cabinet. 2. At the front of the cart, release the Locking pins from their park positions on both sides.
  • Page 22 CCL Rigging components   9. Attach the next cabinet to the previously extended Front links of the first cabinet, reinsert its Locking pins on both sides and ensure the pins are fully inserted and locked. 10. At the rear of the bottom cabinet, insert one Locking pin to the [0°] hole of the center rigging strand.

  • Page 23: E7842 Wheel Board 3 X Ccl-Sub

    CCL Rigging components   2.10.2  E7842 Wheel board 3 x CCL-SUB Pos. Component Description E7842 Wheel board 3 x CCL-SUB Dead weight: 14.2 kg (31 lb) NOTICE! Maximum load: 140 kg (310 lb) Total weight: 148 kg (326 lb) Dimensions: H x W x D (cm): 150 x 60 x 90 H x W x D (inch): 59 x 23.5 x 35  ...
  • Page 24 CCL Rigging components   3. Stack the next cabinet onto the top panel of the first cabinet. 4. On the upper cabinet, release the Rear link. 5. Move the upper cabinet towards the front until the Front links of the lower cabinet fit into the slots at the front of the upper cabinet.

  • Page 25: Temporary Storage

    CCL Rigging components   2.10.3  Temporary storage Touring cart Once the assemblies are set up, the touring carts can be packed and stacked for temporary storage. The top lid of the cart can be stored in the cart tray itself. For this purpose, proceed as follows: 1.

  • Page 26: Ccl Array Assemblies Overview

    3  CCL Array assemblies overview CCL Array assemblies overview         CCL8/CCL12 Line array 8-deep   CCL8/CCL12 Line array   CCL-SUB Column   Mixed CCL array configuration Refer to: 8-deep, Pullback mode setup Refer to: Refer to: Refer to: Þ Chapter 5 “CCL8/CCL12 array Þ Chapter 7 “...

  • Page 27: Array Assembly - Preassembly

    4  Array assembly - Preassembly Array assembly - Preassembly   4.1  Setup preparations Notes ▪ It is assumed that the Touring carts are appropriately loaded and the Flying frame is already attached as described in Þ Chapter 2.10 “CCL Touring cart/ Wheel board” on page 20.

  • Page 28: Ccl8/Ccl12 Array Assembly

    5  CCL8/CCL12 array assembly CCL8/CCL12 array assembly   1. Suspend the Flying frame 1. Suspend the Flying frame according to your onsite requirements. 2. Lift the frame to a suitable working height. 2. Prepare the Flying frame 1. On the Flying frame, release the Locking pin that holds the Rear link in its park position to release the Rear link.
  • Page 29 CCL8/CCL12 array assembly   5. Add the next TOP cabinet 1. Extend the Front links and release the Splay link of the next cabinet. 2. With the front grill facing upwards, attach the front links of the prepared cabinet to the corresponding slots at the front of the upper cabinet on both sides.

  • Page 30: Pullback Mode Setup

    6  Pullback mode setup Pullback mode setup   6.1  Specifications and recommendations NOTICE! Load safety information Only CCL-TOP cabinets can be deployed with any splay angle combination and any total vertical inclination of the entire array using an additional pullback point at the bottom of the array, as long as the conditions described below are met.

  • Page 31: Attaching The Pullback Frame

    Pullback mode setup   6.2  Attaching the Pullback frame The pullback frame is attached on the bottom cabinet, while the Splay link of the cabinet must be in its park position (fully folded in). 1. Lift the assembly to a suitable working height. 2.

  • Page 32: Ccl-Sub Column

    7  CCL-SUB Column CCL-SUB Column   7.1  Limitations NOTICE! A maximum of 10 x CCL-SUB cabinets is allowed to be suspended, including all rigging components. 7.2  SUB column setup 1. Prepare the Flying frame For this type of setup, the Beam extension of the Flying frame has to be attached to its REAR POSITION and the frame's Rear link has to be attached to the SUB POSITION on the Beam extension Attaching the Beam extension to REAR POSITION...
  • Page 33 CCL-SUB Column   3. Release the ring cotter [C] of the fixing bolt [B] and remove the fixing bolt. 4. Take off the Rear link. 5. Attach the Rear link to the dedicated hole position (SUB POSITION) on the Beam extension. 6.
  • Page 34 CCL-SUB Column   4. Attach the Flying frame to the first SUB cabinet To attach the frame onto the first cabinet, proceed as follows: 1. Attach the frame onto the top panel of the cabinet. 2. Move the frame towards the front until the Front links of the cabinet fit into the slots at the front of the frame and the Rear link of the frame fits into the rear rigging strand of the cabinet.
  • Page 35 CCL-SUB Column   5. Move the upper cabinet towards the front until the Front links of the lower cabinet fit into the slots at the front of the upper cabinet 6. Reinsert the Locking pins of the Front links on both sides and both Locking pins at the rear and ensure both pins are fully inserted and locked.

  • Page 36: Mixed Array Setup

      8.1  Remarks and limitations NOTICE! For a mixed setup, the Z5820 CCL Flying frame is used as a suspension device while a second CCL Flying frame is additionally required as adapter frame between SUB and TOP cabinets. The CCL Flying frame allows mixed array configurations with a maximum total system weight of 500 kg (1100 lb) - SWL including all rigging components.

  • Page 37: Order Of Assembly

    Mixed array setup   8.3  Order of assembly The assembly of a mixed array configuration is divided into the following three main procedures: 1. Suspending the desired number of SUB cabinets. 2. Attaching the adapter frame. 3. Attaching the TOP cabinets. 1.
  • Page 38 Mixed array setup   3. On the frame, release the Locking pin that holds the frame's Rear link in its park position. 4. Fold out the Rear link and reinsert the Locking pin. 5. With the front grill facing upwards, attach the front links of the prepared cabinet to the corresponding slots at the front of the frame on both sides.
  • Page 39 Mixed array setup   4. On the second cabinet, preset the desired splay angle (e.g. [2°]). 5. Raise the bottom cabinet until the Splay link of the upper cabinet has engaged into the preset Locking pin of the bottom cabinet. 6.

  • Page 40: Ccl Touring Cart Setup - The Cart Race

    9  CCL Touring cart setup - The cart race CCL Touring cart setup - The cart race   The CCL Touring cart allows for a quick and easy setup of arrays as the entire cabinet assembly stored in the cart can be directly connected to the CCL Flying frame or mounted below already suspended CCL8/CCL12 or CCL-SUB cabinets.
  • Page 41 CCL Touring cart setup - The cart race   2. Attach the Flying frame 1. On the cart, take the Flying frame out of its transport position. 2. Attach the frame onto the first cabinet of the assembly until the Front links fit into the slots at the front of the frame.
  • Page 42 CCL Touring cart setup - The cart race   4. Manually apply and fix the splay angles Due to the compact size and light weight of the cabinets, setting the splay angles is performed cabinet by cabinet while the cart can be kept still fitted.
  • Page 43 CCL Touring cart setup - The cart race   6. Attach the next assembly To attach the next cabinet assembly below already suspended cabinets, prepare the next touring cart in the same manner. 1. Move the cart to its assembly position. 2.

  • Page 44: Ccl-Tops Below Ccl-Subs (Mixed Setup)

    CCL Touring cart setup - The cart race   11. Rig the cabling Connect the cables and link cables according to the number of amplifier channels and cabinets used. ▪ If the amplifiers are already wired and powered on, use their System check functions or Channel mute switches and a test signal to check the correct operation and routing of all channels and cabinets.
  • Page 45 CCL Touring cart setup - The cart race   Additional Front links To allow the Flying frame to be mounted underneath SUB cabinets in a mixed array configuration, two additional Front links together with corresponding Locking pins are enclosed with the Flying frame.
  • Page 46 CCL Touring cart setup - The cart race   3. Apply and fix the splay angles manually Due to the compact size and light weight of the cabinets, setting the splay angles can be performed while the cart is still fitted. 1.
  • Page 47 CCL Touring cart setup - The cart race   7. Rig the cabling Connect the cables and link cables according to the number of amplifier channels and cabinets used. ▪ If the amplifiers are already wired and powered on, use their System check functions or Channel mute switches and a test signal to check the correct operation and routing of all channels and cabinets.

  • Page 48: Ground Stack Setups

    10  Ground stack setups Ground stack setups   WARNING! Potential risk of personal injury and/or damage to material! ▪ Do not set up ground stacks on uneven ground. ▪ Always secure ground stacked setups against movement and possible tipping over. 10.1 ...
  • Page 49 Ground stack setups   5. Move the upper cabinet towards the front until the Front links of the lower cabinet fit into the slots at the front of the upper cabinet. 6. Reinsert the Locking pins of the Front links on both sides and both Locking pins at the rear and ensure both pins are fully inserted and locked.

  • Page 50: Ccl-Top Ground Stack

    CCL-TOP stack or on top of applicable subwoofers. For this purpose, the Z5820 CCL Flying frame or the Z5824 CCL Pullback frame can be used as ground support. 10.2.1  CCL Flying frame as ground support...
  • Page 51 Ground stack setups   2. First cabinet to frame To attach the first cabinet to the frame, proceed as follows: 1. Extend the Front links and release the Splay link of the first cabinet. 2. Attach the first cabinet until the Front supports of the frame fit into the slots at the front of the TOP cabinet.
  • Page 52 Ground stack setups   3. Attach the next (second) cabinet 1. Extend the Front links and release the Splay link of the second cabinet. 2. Attach the second cabinet until the Front links of the first cabinet fit into the slots at the front of the second cabinet. 3.

  • Page 53: Ccl Pullback Frame As Ground Support

    Ground stack setups   5. Check the assembly Recheck the actual status of the entire assembly according to the checklist given in Þ Chapter 11 “Safety and system checks” on page 61. 5. Rig the cabling Connect the cables and link cables according to the number of amplifier channels and cabinets used.
  • Page 54 Ground stack setups   2. First cabinet to frame To attach the first cabinet to the frame, proceed as follows: The required front Locking pins are stored in their park positions on both sides of the Pullback frame. 1. Take off the Locking pins from their park positions. 2.
  • Page 55 Ground stack setups   3. Attach the next (second) cabinet 1. Extend the Front links and release the Splay link of the second cabinet. 2. Attach the second cabinet until the Front links of the first cabinet fit into the slots at the front of the second cabinet. 3.

  • Page 56: Mixed Ccl Ground Stack Setup

    CCL-TOP stack or on top of applicable subwoofers. For this purpose, the Z5820 CCL Flying frame or the Z5824 CCL Pullback frame can be used as ground support. 10.3.1  CCL Flying frame as ground support 1.
  • Page 57 Ground stack setups   Attaching the Beam extension to REAR POSITION 1. On the Flying frame, release the corresponding Locking pin. 2. Fully insert the Beam extension into the rear slot of the frame. 3. Reinsert the Locking pin on the frame. Assembly procedure Beam extension in REAR POSITION Changing the Rear link position...
  • Page 58 Ground stack setups   5. Attach the Rear link to the dedicated hole position (SUB POSITION) on the Beam extension. 6. Insert the fixing bolt. 7. Secure the fixing bolt using the ring cotter and ensure the ring cotter is properly locked. Additional Front links To allow the first cabinet to be mounted onto the Flying frame, two additional Front links together with corresponding Locking pins are...

  • Page 59: Ccl Pullback Frame As Ground Support

    Ground stack setups   3. Attach the TOP cabinets Attaching the TOP cabinets is performed in the same manner as described in Þ Chapter 10.2 “CCL-TOP ground stack” on page 50 following Þ Chapter 10.2.1 “CCL Flying frame as ground support” on page 50. 4. Check the assembly Recheck the actual status of the entire assembly according to the checklist given in Þ Chapter 11 “Safety and system checks”...
  • Page 60 Ground stack setups   3. Attach the TOP cabinets Attaching the TOP cabinets is performed in the same manner as described in Þ Chapter 10.2 “CCL-TOP ground stack” on page 50 following Þ Chapter 10.2.2 “CCL Pullback frame as ground support” on page 53. 4. Check the assembly Recheck the actual status of the entire assembly according to the checklist given in Þ Chapter 11 “Safety and system checks”...

  • Page 61: Safety And System Checks

    11  Safety and system checks Safety and system checks   Before hoisting the array to its operating position, recheck the actual status of the assembly. When applicable, the same safety and system checks also apply to mixed array configuration and/or ground stack assemblies. 11.1 ...

  • Page 62: Hoisting, Aiming And Securing The Array

    12  Hoisting, aiming and securing the array Hoisting, aiming and securing the array   12.1  Hoisting the array WARNING! Potential risk of personal injury and/or damage to material! Always ensure that each of the hoists is able to carry the total weight of the array.

  • Page 63: Vertical Aiming

    Hoisting, aiming and securing the array   12.2.1  Vertical aiming Application example To take an example: ArrayCalc indicates a frame angle of –3.6° vertically. 1. When you use ArraySight to measure this angle, you raise the first array to its operating height and then check the meter unit screen.

  • Page 64: Derigging

    13  Derigging Derigging   WARNING! Potential risk of personal injury and/or damage to material! In particular, make sure that when lowering the array nobody is directly underneath or in the vicinity of the array. When lowering the array, avoid diagonal pull. This could lead to the potential risk of the array tipping over towards the front.

  • Page 65: Care And Maintenance

    14  Care and maintenance Care and maintenance   14.1  Transport/Storing During transport ensure the rigging components are not stressed or damaged by mechanical forces. Due to their surface treatment the rigging components are temporarily protected against moisture. However, ensure the components are in a dry state while stored or during transport.
  • Page 66 Care and maintenance   Ring cotters ▪ Visual inspection for obvious damage and deformation. ▪ Functional test of the locking mechanism as described in Þ Chapter 2.7 “Ring cotters” on page 15. If a ring cotter can no longer be properly fitted to the fixing bolt and locked, it must be exchanged.

  • Page 67: Manufacturer's Declarations

    ▪ Z0882 CCL12 ▪ Z0884 CCL-SUB d&b CCL rigging components (including all additional components) ▪ Z5820 CCL Flying frame ▪ B2487.K07.00 CCL Load adapter (enclosed item) ▪ B2487.K08.00 CCL Load adapter Rota Clamp (enclosed item) ▪ E5041.300.00 CCL Load adapter (spare part) ▪...
  • Page 68 www.dbaudio.com...

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