Comeup CP-200 User manual

Electric Winch
1
Limited One (1) Year Warranty Statement
Comeup Industries Inc. ( ) warrants to the original purchaser that the mechanical compnents
and electrical components of the Electric Winch will be free of defects in material and
workmanship for one (1) year. All mounting kits and other accessories carry one (1) year
limited warranty against defects in material workmanship.
This Warranty applies only to the original purchaser of the winch. To obtain any warranty service, the
Purchaser under this Limited Warranty is requested to report or his authorized distributors
of any claims. The Purchaser must provide a copy of the proof of purchase bearing the winch serial
number, date of purchase, owners name email, or Tel & Fax, address and registration number. Any
product determines to be defective will be repaired or replaced at sole discretion
without charge to Buyer upon Buyer’s compliance with these procedures. Seller or its Authorized
Distributors may make reasonable charges for parts and labour for repairs not covered by this Limited
Warranty.
takes the responsibility for all parts and components to be free from defects in materials and
workmanship, but the following are hereby excluded and disclaimed:
(1). All warranties of wire rope assemblies after initial use.
(2). All warranties of fitness for a particular purpose.
(3). All warranties of the product’s finish
(4). All warranties of merchantability
The Limited Warranty does not cover any failure that results from improper installation, operation or
the Purchaser’s modification in design. reserves the right to change Product design without
notice. In situations in which has changed a product design, shall have no
obligation to upgrade or otherwise modify previously manufactured products.

Electric Winch
Thank you for purchasing a Winch. This manual covers operation and maintenance of
the winch. All information in this publication is based on the latest production information available at
the time of printing.
General Safety Precautions
The winch has been designed to give safe and dependable service if operated according to the
instructions. Please read and understand this manual before installation and operation of the winch.
Follow these general safety precautions:
Confirm that the winch complies with the using conditions.
Keep the winch secure strongly and the rope is not wound to be deviated to the drum.
Don't use unsuitable pulleys or accessories concerned.
Don't use unsuitable rope in construction, strength or having any defects.
Pay attention to the grounding, it provides a path of least resistance for electric current to reduce
the risk of shock.
Check the winch for smooth operation without load before loading operation.
Make sure the wire rope to be wound evenly in the first layer on the drum, rewind it if a mixed
windings in existence.
If a wire rope is found an uneven winding or accumulated at one side of the drum, align it adequately.
1. The winch is not to be used to lift, support or otherwise transport personnel.
2. A minimum of five (5) wraps of rope around the drum is necessary to support the load rated.
3. The owner and/or the operator shall have an understanding of these operating instructions and the
warning before operating the electrical winch. Failure to follow these warnings may result in loss of
load, damage to the winch, property damage, personal, or fatal injury.
4. The owner shall retain this manual for further reference to important warnings, installation, operating
and maintenance instructions.
2
WARNING
！

I.Installation Precaution
3
General Safety Precaution
● Low temperature below -10℃ ,high
temperature above 40℃ or humidity
above 90% conditions
※Cause malfunction of spare parts ※Cause explosion
● In heavy acid or salty conditions
● In rain or snow conditions
● In a heavy general powder
※Cause malfunction of performances
● In an organic chemistry or explosive
powder conditions
※Cause malfunction of spare parts
※Cause rust or short circuit
！DANGER
The following environmental conditions may result in the possible causes of hoist trouble.

II. Handing Precautions
4
● It is forbidden to lift loads above
the rated capacity of the winch
● Do connect the power lead on the
main power source directly and
fasten them
● Ban on transporting persons ● Don’t ignore fault accessories
● Don’t stand under winching
operation
● Don’t operate hoist in rain or snow
● Do perform maintenance on
schedule
● Do anchor crane with ballasted
container and wire rope

III. Winching Principles
5
Percentage Duty Cycle
Load Rated
The life of the winch is depending on the conditions of the load and working frequency.
In the long time operation, make sure to use the machine within its continuous ratings.
Continuous ratings means the percentage duty cycle (%ED) is subject to the rated voltage,
rated frequency and a 63% of rated load.
Percentage duty cycle (%ED)＝ X 100 (%)
Tb: total sum of overall loadings operating hours.
Ts: total sum of stopping hours.
Tb + Ts = approximately 1 to 10 minutes.
For this reason, all electric winches are rated at a 25% percentage duty cycle (%ED).
Load and speed vary according to how
much wire rope is on the drum. The first layer
of rope on the drum delivers the slowest speed
and the maximum load. A full drum delivers the
maximum speed and the minimum load. For this
reason, all electric winches are rated at their
top layer of wire rope on the drum.
Calculating Head Loads
Use a tackle block for double fall operation to increase the rated load by approximately
85% but its speed will be deducted by half accordingly.
P: Rope tension
η: Sheave efficient
θ: Angle
W: Load
μ: Friction factor
！WARNING
Never hoist over the rated percentage duty cycle.
First layer (Min.speed Max.load)
Half layer (Med.speed Med.load)
Top layer (Max.speed Min.load)
Flange of drum
P
W
P= W
η
P
W
P= W
2η
P
P= W
4η
W
P
WP= W
μ.
μ
P
μ
W
θ
P= Wμ.. sinθ +W.cosθ
Tb
Tb + Ts

6
Calculating Fleet Angle
● The winch should be mounted as close to centre
and as perpendicular as possible to the direction
of the line pull. This will keep the wire rope fleet
angle centre on the drum as small as possible.
● If the proper fleet angle is not maintained, the wire
rope could wind onto one side of the drum.
Experience has shown that the best wire rope service is obtained if the maximum fleet angle
is not more than 1.5° for smooth drum and 2° for grooved drum.
For example, the correct distance varies according to drum length.
D/d Ratio
It means ratio of pitch circle diameter of drum to the rope diameter.
In principle, a 12:1 D/d ratio is suggested for most pulling application and a 15:1 D/d ratio for
lifting and lowering applications. For example, a CP-200 comes with a 94 mm dia. drum and
a 6 mm x 30 m wire rope, therefore its D/d ratio is calculated as follow.
D/d ratio = ( 94 + 6 mm ) / 6 mm = 16.67 times
Rope Safety Factor
The working coefficient of the wire rope shall be determined from the ratio of the minimum
breaking force of the rope and the maximum possible lifting capacity.
In principle, a 3.5 times of rope safety factor is suitable for most pulling applications and a 5
times for lifting and lowering applications. For example, a CP-200 comes with a 6 mm x 30 m
wire rope with 2,010 kg minimum breaking force, therefore its rope safety factor is calculated
as follow.
Rope safety factor = 2,010 kg / 200 kg = 10 times
θ
θ
Correct Distance
Drum Length
Fleet Angle
Model CP-200/250/300,
CWG-30075 CP-500/500T CWG-10077 CWG-10151/30151,
CP-750T/900T
Drum Length 110 mm 220mm 150 mm 240 mm
Correct
Distance
2.09 m
at least
4.18 m
at least
2.85 m
at least
4.56 m
at least
Model CWG-30375 CWG-30565 CWG-30750 CWG-31500 CWG-34000
Drum Length 230 mm 312 mm 312 mm 405 mm 680 mm
Correct
Distance
2.09 m
at least
5.92 m
at least
5.92 m
at least
7.7 m
at least
12.92 m
at least

IV. Compliance with EU Directives
7
Electric Winches shall comply with the following regulations
1. European Standards of EN 14492-1 for Power Driven Winches came to effect from 29th.
December 2009
2. European Machinery Directive 2006/42/EC.
3. European Directive on Electromagnetic Compatibility ( EMC ) 2004/108/EC
4. European Low Voltage Directive ( LVD ) 2006/95/EC
To comply with EN 14492-1, the following optional accessories must be fitted
to all winches
•Low voltage control •Rope drum cover
•Remote control w/ an emergency stop button •Up and down limits protection devices
When using and installing a winch, the owner or end user shall ensure that all legal requirements
are completely complied with.
Extracts from the Directives
1. EN 14492-1 Section 5.15.6 Wire Rope
Wire rope minimum break to be twice winch rating
2. EN 14492-1 Section 5.7.2 Rope Drum
Rope drum mean diameter to be 10 times the diameter of the wire rope and the flanged
drum end plates shall protrude beyond the rope wound on the drum at the top layer by at
least 1.5 x the nominal rope diameter.
3. EN 14492-1 Section 5.7.6 Rope Fastening onto the rope drum
Rope attachment to withstand 2.5 times the winch rating
Rope must have at least two wraps winding before fixing point
4. EN 14492-1 Section 5.15.5 Brake
Winch to hold full rated load
5. EN 14492-1 Section 5.15.2 Rated Capacity Limiters
Winch for lifting and lowering purpose with a rated capacity of 1,000 kg or more shall be
fitted with a rated capacity limiter to prevent overloading of the winch
d
10:1 D/d ratio
at least 5 wraps
fixing point
freeboard >1.5d

V. Working Method
8
Power Lead and Switch Cord Sections
Pendant Switch Selections
Low Voltage Control Selections
Remarks: 1.＊means standard version on delivery.
2. Switch PB-331 and PB-306 are equipped with an emergency stop function.
3. The selections of LV-320 and LV-360 vary according to winch model and power source.
4. The length of power lead is subject to the distance less than 20 meters.
5. The length of switch cord is subject to the distance less than 20 meters.
6. For any other cases, please use a bigger section of power lead or switch cord.
Remarks: 1.＊means standard version on delivery.
Winch Model Power Lead
Remote Control
Low
Voltage
Control
Direct Control Indirect Control
W/Switch
CPB-213
W/Switch
PB-331
W/Switch
CPB-161
W/Switch
PB-306
LV-320 or
LV-360
CP-200/250/300 1.5 mm
2
1.25 mm
2
2.0 mm
2
1.25 mm
2
CP-500 3.5 mm
2
3.5 mm
2
3.5 mm
2
1.25 mm
2
CP-500T 3.5 mm
2
3.5 mm
2
3.5 mm
2
1.25 mm
2
1.25 mm
2
CP-750T 3.5 mm
2
1.25mm
2
1.25mm
2
1.25 mm
2
CP-900T 3.5 mm
2
1.25 mm
2
CWG-10077 3.5 mm
2
3.5 mm
2
1.25 mm
2
CWG-30075 3.5 mm
2
1.25 mm
2
2.0 mm2 1.25 mm
2
CWG-10151 5.5 mm
2
3.5 mm
2
3.5 mm
2
3.5 mm
2
1.25 mm
2
CWG-30151 3.5 mm
2
2.0 mm
2
2.0 mm
2
1.25 mm
2
CWG
CWG-34000
-30375/30565/
30750/31500 5.5 mm
2
1.25mm
2
1.25 mm
2
8.0 mm
2
1.25mm
2
1.25 mm
2
Switch Type Direct Control Indirect Control
*CPB-213 PB-331 *CPB-161 PB-306
Rated Amp. 30 A 30 A 3 A 3 A
Contacts 3a 3a + Emergency
Stop ( 1a1b) 2a 2a + Emergency Stop ( 1a1b)
Applicable
Winches
CP-200/250/300/500/500T,
CWG-10077/10151/30075/30151
CP-750T/900T, CWG-30375/30565
CWG-30750/31500/34000
Type LV-320, Plastic Cover LV-360, Steel Cover
IP Grade IP55, Comes with magnetic switch,
relay and transformer
IP44, Comes with magnetic switch,
relay and transformer
Ratings 5 kw 7.5 kw 7.5 kw 15 kw
Applicable
Winches
CWG-30375,
CP-750T/900T
CWG-30565/30750
31500,380-440V
CWG-30565/30750
31500,220V
CWG-34000
＊LV-320
＊LV-320
＊LV-320 or
LV-360
＊LV-360

9
Grounding
To prevent the risk of electric shock, the power plug must be plugged into a matching outlet
and grounded in good condition.
Up and Down Switching
To lift a load, press ↑ button and drum will rotate as shown below operation.
To lower a load, press ↓ button and drum will rotate as shown below.
To stop winching, release ↑or ↓ button.
To have an emergency stop function, press the emergency stop button (option). Rotate the
button clockwise for returning.
Wire Rope Replacement
● Insert the wire rope into the hole of drum and fix it with a P. T. screw, then press ↑ button
of switch for rotate the drum in the lifting direction.
● Wind the wire rope accurately around the drum, and an irregular winding will cause the load
to be swing, thus damaging the wire and reducing the life of winch.
● When replacing the rope w/weight hook for winch rated less than 500 kg, according to the
following procedures. It is only available for CP-200/250/300/500S/500T and CWG-10075/
10151/30075.30151
*Pull out an R-dowel "D" from the round head pin "C".
*Pull out a round head pin "C" from hook body "A".
*Put a wire rope "B" into the hole of hook body "A", and insert a round head pin "C" through
wire rope and fixture hole of hook body "A".
*Insert an R-dower "D" into the hole of round head pin "C".
Wire drum
Wire rope
Lifting direction
Down button
Wire drum Rotation
(Lifting direction)
DOWN
Up button
Wire drum Rotation
(Lifting direction)
UP

10
Wire Rope Selections
Oil Replacement
Gear lubrication is an important component in insuring the long life of your winch. Winch
are pre-lubricated at the factory and do not require initial lubrication. Re-lubrication interval
depends upon service, 250 working hours of a year, or after repair or disassembly. The lubricant
for gear box was recommended by Castrol Alpha Spheerol L-EP 2 or HT-740-0 grease, or
Castrol Alpha Series, SP-220/460 oil recommended.
Remarks: The recommended wire rope means standard version on delivery. Other size wire
rope shall carefully consider the safety factor and D/d ratio for rope...
Winch Model
Lifting
Capacity
at 50Hz kg
Recommended Wire Rope
Dia.
mm
Length
( m ) Const.
Minimum
Breaking
Strength kg
Safety
Factor at
50Hz
CP-200 200 6 30 6 x 19 2,010 10
CP-250 250 6 30 6 x 19 2,010 8
CP-300 300 6 30 6 x 19 2,010 6.7
CP-500/500T 500 7 60 6 x 19 2,700 5.4
CP-750T 750 9 60 6 x 24 3,750 5
CP-900T 900 10 30 6 x 24 4,640 5.1
CWG-10077 300 6 60 6 x 19 2,010 6.7
CWG-10151 400 9 60 6 x 24 3,750 9.3
CWG-30075 300 6 30 6 x 19 2,010 6.7
CWG-30151 500 9 60 6 x 24 3,750 7.5
CWG-30375 900 10 60 6 x 24 4,640 5.1
CWG-30565 1,100 12 100 6 x 24 6,680 6
CWG-30750 2,200 16 100 6 x 24 11,900 5.4
CWG-31500 3,500 18 150 6 x 24 15,000 4.2
CWG-34000 5,000 22.4 200 6 x 24 23,300 4.6
Model
CP- 200 250 300 500 500T 750T 900T CWG-30075
Lubricant L-EP2 L-EP2 L-EP2 L-EP2 L-EP2 HT-740-0 HT-740-0 L-EP2
Q’ty 0.5 lt 0.5 lt 0.5 lt 0.5 lt 0.5 lt 0.74 lt 0.74 lt 0.5 lt
Model
CWG- 10077 10151 30151 30375 30565 30750 31500 34000
Lubricant L-EP2 HT-740-0 HT-740-0 HT-740-0 HT-740-0 HT-740-0 SP-460 SP-460
Q’ty
0.74 lt 0.74 lt 0.74 lt 1.36 lt 2.27 lt 3.41 lt 3.14 lt 3.14 lt

11
Brake Replacement and Adjustment
● For CP-200/250/300/500/500T, CWG-30075 winches
There is no brake adjustment function. Once the brake disc is considerable worn, replace it
with new one.
Condition: Brake distance is more than 1.5% of rope length to be wound-in during 1 min or
the brake disc thickness is smaller than 8.5 mm, compared to the standard thickness
of 9 mm
● For CP-750T/900T, CWG-10151/30151/30375/30565/30750/31500/34000 winches
If the brake disc thickness is smaller than 12 mm, replace it with new one, compared to the
standard thickness of 14 mm, replace it with new one.
Condition: Brake distance is more than 1.5% of rope length to be wound-in during 1 minute.
Procedures: Step1. Loosen the adjusting nut “B” to have the nut ”A” released
Step2. Rotate nut ”A” clockwise to get a proper brake gap
0.35 mm for CWG-10151/30151
0.45 mm for CP-750T/900T and CWG-30375
0.6 mm for CWG-30565/30750/31500/34000
Step3. Tighten the adjusting nut “B”
Step4. At first, tighten the adjusting nut C and then release it by proper wraps
CWG-10151/30151…………………..9.5 wraps
CWG-30375…….………………..…...5.5 wraps
CWG-30565/30750/31500/34000…..6.5 wraps
CP-750T/900T…………………………6.5 wraps

12
Brake Specification
Model Coil Volt.
V
Brake Disc
Diameter
mm x q’ty
Resistance
Ohm
Black & Blue wires
Brake Gap
mm
CP-200
110
95 x 1
103
0.3
CP-250
110
95 x 2
103
0.45
CP-300
220
95 x 2
103
0.45
CP-500
220
95 x 2
228
0.45
CP-500T
220
95 x 2
228
0.45
CP-750T
380
150 x 1
84
0.45
CP-900T
380
150 x 1
84
0.45
CWG-10077
110
95 x 2
64
0.45
CWG-10151
DC 220
140 x 1
436
0.35
CWG-30075
220
95 x 2
434
0.45
CWG-30151
DC 220
140 x 1
436
0.35
CWG-30375
220
170 x 1
25
0.45
380
68
415
105
440
115
CWG-30565
CWG-30750
CWG-31500
220
188 x 2
28
0.6
380
60
415
90
440
126
CWG-34000
220
200 x 2
9
0.6
380
27
415
41
440
152

VI. Cart Puller Capacity
13
Choose the Right Winch
In most pulling applications you are dealing with a rolling road rather than pulling a dead
weight. Resistance to rolling is mostly influenced by the load, rolling resistance, track gradient,
track curvature, track conditions.
● Load: Calculate the total weight of the loaded cart to be moved simultaneously.
● Rolling resistance: Resistance to rolling is influenced by the wheel journals, type of
lubrication used and the ambient temperature.
● Track gradient: For each one percent gradient, a rise of one meter for every 100 meter of
track, the running line pull must be increased by 10 kg per ton.
● Track curvature: To overcome the effects of wheels binding against rails on curved sections
of track, running line pull must be increased. For each degree of curvature,
the running line pull must be increased by 1kg per ton.
● Track conditions: The condition of substandard track can vary considerably.
Application Condition Example
1).Pulling of a rolling cart in and out of an oven using a single wire rope
2).50 ton total load being moved included weight of cart
3).Steel cart wheels with precision wheel bearing
4).New track, 5°curvature and 2% gradient
Pulling Capacity Required
50 ton…..…….….………Total weight being moved
x (10 kg+20 kg+5 kg) 10kg…......Pull required per ton being moved
1,750 kg 20kg…......For each one percent gradient, the running line pull
must be increased by 10 kg/ton
5kg……......For each one degree of curvature, the running line
pull must be increased by 1 kg/ton
x 1.2 20%…….. contingency for unpredictable track or cart conditions
2,100 kg …..…...........Minimum calculated cart puller capacity
5% 3°
10%
6°
20%
11°
30%
17°
50%
26°
70%
35°
100%
45°
(θ)
Gradient (%) = X 100 (%)
Height
Distance
Gradient
Gradient
Percentage Gradient
Height
Distance
A gradient of 10% is a rise of one meter in ten meters

VII. Wiring Diagram
14
CP-200/250/300, CWG-10077 Winches
Standard Version
Low voltage control assembly and Switch with an emergency stop button
Switch with an emergency stop button
Blue
Brown
Gray
Red
Black
Up
Down
Brown / Red
Blue / Black
Power Supply
Motor
Brake
Grounding
Pendant Switch CPB-213
220/230/240V
220/230/240V
Motor
Blue
Brown
Gray
Red
Black
Brown / Red
Blue / Black
Power Supply
Up
Down
Brake
Emergency Stop
Grounding
Pendant Switch PB-331
CP-750T Winch
Standard Version Switch with an emergency stop button
The horizontal load reversing allows 2 pieces
of wire rope to be spooled onto the first layer
of grooved drum. As one rope winds onto the
drum and the other rope winds off an equal
amount. It is important to know how each of
the wire rope will be coming off of the drum, that allows the correct grooving to be provided.
Horizontal Load Reversing

15
CP-500T Winch
Low voltage control assembly Low voltage control assembly and
Switch with an emergency stop button
Pendant Switch CPB-213
Up
Down
Blue
Brown
Gray
Red
Black
Quick Connector
U1
U2
V1
R
T
Motor
Blue
Brown
Gray
V2
S
Red
Black
380V
U1
U2
V1
R
T
Motor
Blue
Brown
Gray
V2
S
Red
Black
U5 V5
400/415V
Pendant Switch CPB-213
Up
Down
Blue
Brown
Gray
Red
Black
Quick Connector
Quick Connector
U1
U2
V1
R
T
Motor
Blue
Brown
Gray
V2
S
Red
Black
380V
U1
U2
V1
R
T
Motor
Blue
Brown
Gray
V2
S
Red
Black
U5 V5
400/415V
Quick Connector
Up
Down
Pendant Switch PB-331
Emergency Stop
Black
Red
Gray
Brown
Blue
Up
Down
Pendant Switch PB-331
Emergency Stop
Black
Red
Gray
Brown
Blue
Standard Version Switch with an emergency stop button

16
CWG-10151 Winch
Low voltage control assembly and Switch with an emergency stop button
Up
Down
Pendant Switch CPB-213
Red
Black
Gray
Blue
Brown
Power Supply
Grounding
Motor
Brake
T
R
220~240V
Black
White
Red
Black
Gray
Blue
Brown
Power Supply
Grounding
Motor
Brake
T
R
230~240V
Black
White
Up
Down
Emergency Stop
Pendant Switch PB-331
Standard Version Switch with an emergency stop button
CP-500 Winch
Standard Version
Low voltage control assembly and Switch with an emergency stop button
Switch with an emergency stop button
220/230/240V
Motor
Brown
Red
Black
Blue
Gray
Pendant Switch CPB-213
Up
Down
Blue
Brown
Gray
Red
Black
Quick Connector
Brake
R
T
Up
Down
Pendant Switch PB-331
220/230/240V
Motor
Brown
Red
Black
Blue
Gray
Quick Connector
Brake
Emergency Stop
Black
Red
Gray
Brown
Blue
R
T

17
CWG-30075 Winch
Switch with an emergency stop button Low voltage control assembly and
Switch with an emergency stop button
Up
Down
Pendant Switch CPB-213
Red
Black
Gray
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
200~220V
Black
White
Up
Down
Pendant Switch CPB-213
Red
Black
Gray
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
380V
Black
White
Up
Down
Pendant Switch CPB-213
Red
Black
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
400~415V
Red
Black
Gray
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
380V
Up
Down
Emergency Stop
Pendant Switch PB-331
Black
White
Standard Version
CWG-30375/30565/30750/31500 Winches
Standard Version Switch with an emergency stop button

18
CWG-30151 Winch
Switch with an emergency stop button
Low voltage control assembly and Switch with an emergency stop button
Up
Down
Pendant Switch CPB-213
Red
Black
Gray
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
380V
Black
White
Up
Down
Pendant Switch CPB-213
Red
Black
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
415V
White
Black
Red
Black
Gray
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
380V
Up
Down
Emergency Stop
Pendant Switch PB-331
Black
White
Red
Black
Blue
Brown
Power Supply
Grounding
Motor
Brake
S
R
T
400~415V
White
Black
Up
Down
Emergency Stop
Pendant Switch PB-331
Standard Version
CWG-34000 Winch
Standard Version Switch with an emergency stop button