Comeup CWG-10077 User manual

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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
Winch is designed to give safe and dependable service if operated according
to the instructions. 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.
The winch is not to be used to lift, support or otherwise transport personnel.
A minimum of five(5) wraps of rope around the drum is necessary to support the load
rated.
WARNING

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Environment Precautions
DANGER
●The following environmental conditions may result in the possible
causes of winch trouble.
●Low temperature ●In a organic
below -10℃,high chemistry or
temperature explosive powder
above 40℃or condition
humidity above
90% conditions
※Cause malfunction of spare parts ※Cause explosion
●In heavy acid or salty
conditions ●In a heavy general powder
※Cause malfunction.
of spare parts
●In the rain or snow
※Cause rust or
short circuit ※Cause malfunction
of performances

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I. Specification & Standard Accessories
1-1. Specification
Drum Size(mm) Load Rated
(kg) Speed(M/min)
Model Gear
Ratio
Width
Empty
Drum
Diameter
Full
Drum
Diameter
50Hz 60Hz 50Hz 60Hz
Motor
Kw x p
Power
Source
Percentage
Duty Cycle
10077 41:1 150 102 180 300 250 12 ~ 18 14 ~ 20 1.5 x 4
10151 57:1 240 140 280 400 350 12 ~ 18 14 ~ 21 1.5 x 4
1 Phase
220V
230V
240V
30075
30075B
43:1 110 94 154 300 250 10 ~ 15 12 ~ 18 0.75 x 4
CWG-
30151 57:1 240 140 280 500 400 12 ~ 18 14 ~ 21 1.5 x 4
3 Phase
200V
220V
380V
400V
415V
440V
25% ED
(60 times/h
maximum
starting
Frequency)
* 30075B were equipped with switch socket
Percentage duty cycle: The ratio of overall operating hours of motor to the working hours including the pause hours of the
motor. It’s expressed by percentage. Percentage Duty Cycle (%ED)= Tb x100(%)
Tb+Ts
Tb=Total sum of loading hours Ts=Total sum of stopping hours Tb + Ts = Approximately 1 to 10 min
1-2. Standard Accessories
Remote Control Weight Hook
Model Wire Rope
24 VAC
Control
Box
CPB-213 PB-306 CWH-0031 CWH-0005
Base
Plate
10077 Ø6mm x 45M ˇˇ
10151 Ø9mm x 60M ˇˇˇ
30075
30075B
Ø6mm x 30M Option
ˇOption
ˇ
CWG-
30151 Ø9mm x 60M Option
ˇOption
ˇˇ

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II. Performance Data
2-1. CWG-10077/10151
Model CWG-10077 CWG-10151
Motor kw x p 1.5 x 4 1.5 x 4
mm 7 9.0Wire
Rope
Size Breaking kg 2,010 3,750
50Hz 433 593Ratged Load
(kg) 60Hz 361 519
50Hz 12.0 12.0
Speed (m/min)
60Hz 14.0 14.0
1st
Layer
Rope-Winding
Cumulating Sum (m) 8.1 12.0
50Hz 390 529
Ratged Load (kg)
60Hz 325 463
50Hz 13.5 13.6
Speed (m/min) 60Hz 15.5 15.6
2nd
Layer
Rope-Winding
Cumulating Sum (m) 17.2 25.5
50Hz 355 477
Ratged Load (kg)
60Hz 296 418
50Hz 14.8 15.1
Speed (m/min) 60Hz 17.1 17.3
3rd
Layer
Rope-Winding
Cumulating Sum (m) 27.1 40.4
50Hz 325 435
Ratged Load (kg)
60Hz 271 381
50Hz 17.2 16.6
Speed (m/min) 60Hz 18.6 19.0
4th
Layer
Rope-Winding
Cumulating Sum (m) 38.0 56.8
50Hz 300 400
Ratged Load (kg)
60Hz 250 350
50Hz 18.0 18.0
Speed (m/min) 60Hz 20.0 21.0
5th
Layer
Rope-Winding
Cumulating Sum (m) 45 60
In usual cases, the increase of winding layers
of rope accompanies the increase of required motor output.
Torque(T):Torque is a twisting force.
Torque causes rotation of a shaft, or it will set up a twist in a
stationary shaft. It is generally expessed in Newton-Meters.
T: Torgue
T=F x R R: Radius
F: Load

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2-2. CWG-10151/30075/30151
Model CWG-30075/300075B CWG-10151
Motor kw x p 1.0 x 4 1.5 x 4
mm 6 9.0Wire
Rope
Size Breaking kg 2,010 3,750
50Hz 440 741Ratged Load
(kg) 60Hz 370 593
50Hz 10.0 12.0
Speed (m/min)
60Hz 12.0 14.0
1st
Layer
Rope-Winding
Cumulating Sum (m) 5.4 12.0
50Hz 396 661
Ratged Load (kg)
60Hz 330 529
50Hz 11.3 13.6
Speed (m/min) 60Hz 13.6 15.8
2nd
Layer
Rope-Winding
Cumulating Sum (m) 11.5 25.5
50Hz 358 597
Ratged Load (kg)
60Hz 298 477
50Hz 12.5 15.1
Speed (m/min) 60Hz 15.1 17.3
3rd
Layer
Rope-Winding
Cumulating Sum (m) 18.3 40.4
50Hz 326 544
Ratged Load (kg)
60Hz 272 435
50Hz 13.8 16.6
Speed (m/min) 60Hz 16.5 19.0
4th
Layer
Rope-Winding
Cumulating Sum (m) 25.7 56.8
50Hz 300 500
Ratged Load (kg)
60Hz 250 400
50Hz 15.0 18.0
Speed (m/min) 60Hz 18.0 21.0
5th
Layer
Rope-Winding
Cumulating Sum (m) 30 60

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Ⅲ
ⅢⅢ
Ⅲ. Instruction For Installation
3-1. Load Rated
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,winches are rated at
their full drum capacities.
3-2. Calculating Head Load
ηsheave coefficient:
No. of sheaves 1 2
Roller bearing 0.98 0.96
Sleeve bearing 0.96 0.92
3-3. Cart Puller Capacity
Resistance to rolling is mostly
influenced by the gradient of angle, type of tracks and carts condition.
For each one percent gradient. a rise of one meter for meter for every 100
meter of track.


Application Condition
1).Horizontal dual direction pulling of
a rolling cart in and out of an oven
using a single wire rope extending
from the winch drum
2).10 ton total load being moved
included weight of cart
3).Rolling steel on steel
4).New track, no curves and 2% gradient


Cart puller calculator
Required cart puller capacity
10 ton… total weight being moved
X (10kg+20kg) 10kg….Pull required per ton being moved
300 kg 20kg….Pull required for 2% gradient
X 1.2 ….20% contingency for unpredictable track or cart conditions
360 kg …..Minimum calculated effort to pull the cart of 10 ton.
….. Selected a CWG-10151 for 1 phase or a CWG-30151 for 3 phase
Width
Fleet Angle
Correct Distance

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3-4.Calculating Fleet Angle
The winch should be mounted as close to center and as perpendicular as possible
to the direction of the line pull. This will keep the wire rope fleet angle centered
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. This could cause failure of the winch or wire rope, resulting in
damage, injury or death.
Experience has shown that the best wire rope service is obtained when the
maximum fleet angle is not more than 1.5∘for smooth drums.
The distance from centre of the rope drum till the first rope sheave or roller fairlead
shall in the ideal case be 19 times the drum width.
Fleet angle of 1.5∘is the equivalents of approximately 19 cm of lead for each
centimeter of overall drum width.
Model Drum Width (mm) Fleet Angle Correct Distance (m)
CWG-10077 150 2.9
CWG-10151 240 4.6
CWG-30075/30075B 110 2.1
CWG-30151 240
1.5°
4.6
3-5. Lubricant Specifications
All moving parts in the winch are permanently lubricated at the time of
assembly. Under normal conditions factory lubrication will suffice. If
re-lubrication is necessary after repair or disassembly use Castrol Alpha
Spheerol L-EP 2 grease, 150 Viscosity (cSt) at 40∘
∘∘
∘C.
3-6. Cable Selection
Remote Control
Model Power Lead CPB-213
assembly
PB-330
Assembly
PB-306
assembly
CWG-10077 3.5mm23.5mm23.5mm2*
CWG-10151 3.5mm23.5mm23.5mm2*
CWG-30075 1.25mm2* 1.25mm2
CWG-30075B 3.5mm22.0mm2* 2.0mm2
CWG-30151 3.5mm22.0mm2* 2.0mm2
The length of power lead are subject to the distance less than 30 meters.
The length of switch lead are subject to the distance less than 3 meters.
For any other cases, the lead should use a bigger section or adopt a magnetic switch.

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Ⅳ
ⅣⅣ
Ⅳ. Handing Precautions

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Ⅴ
ⅤⅤ
Ⅴ. Maintenance and Inspection
5-1. Checking Reference 1
Classification of checks
Periodical
Daily
One
month
Three
month
One
year
Checking Item Checking Method Checking Reference
◎Marking Lable and the like Visual Existence of label
◎
Winding-in
direction of wire
rope
Visual , measuring
Fleet angle
θ=within 1.5 degree
◎
Installation
Loosing and centre
run-out foundation
Checking of
installing bolts
Existence of
abnomalities
◎Working Manual Reasonable actuation
◎Condition of
clamping of wiring
Decomposition
checking
Confirming of
accuracy of fastening
condition
◎
Wearing of
contact point
Decomposition
checking
To be free from
remarkable wearing
and damage
◎
Outer damage of
lead Visual
To be free from
exposure of
conductive wire
◎◎
Attaching
condition of earth
line
Visual
Existence of
abnormalities of
connecting wires
◎
Control/Switch
Condition of
insulation
Measure with 500v
insulation-
Resistance tester
1MΩmin
◎Condition
of insulation
Measure with
resistance tester
1MΩmin
◎
Motor
Staining damage
Decomposition
check
Existance of
abnormalities
◎Loosing of set
screws
Decomposition
check
To be free from
loosening
◎Wearing of lining
Decomposition
check
To be free from
remarkable wear and
damage
◎◎
Brake
Performance Visual
Distance to be not
more than 1.5% of
rope length to be
wound-in during 1
minute
◎Damage , wearing
Decomposition
check
To be free from
remarkable wear and
damage
◎
Gear
Condition
of grease feeding
Measuring
Existence of
suitability of amount
and deterioration
with grease Mobilux
EP2.Shell Unedo 2 or
Esso Beacon EP2

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5-2. Checking Reference 2
Classification of Checks
Periodical
Daily
One
month
Three
month
One
year
Checking Item Checking Method
Checking
Reference
◎
Breaking of base
wire Visual Less than 10%
◎
Decreasing of
diameter Visual 7% of normal
diameter max
◎
Kink phenomena
run-
out of
foundation
Visual
To be free
from kink
phenomena
◎Deforming or
corrosion Visual To be not remarkable
◎
Fastening condition
of end Visual
To be
sufficient for
hanging up of
load
◎
Condition of rope
winding-in Visual
To be free
from irregular
winding
◎Condition of feed
oil Visual
To be not
insufficient in
feed-out
◎
Wire Rope
Confirming of dead
turn of rope Visual
Confirming of
normalities of
operating-out
◎◎Frame Structure Visual
To be free
cracks,
rupture
harmful
deforation
◎◎Reture of flange
Visual
To be free
cracks,
rupture,
harmful
deforation
◎
Drum
Wear of drum Visual
To be free
from
remarkable
wearing
◎Rotary direction
Visual
Winding-in
direction is
normal
◎Rotary abnormal
sound Hear out
To be free
from
oscillation
and impact
sound
◎
Operation
Over load test Working Existence of
abnormalities

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Ⅵ
ⅥⅥ
Ⅵ. Trouble Shooting
6-1. Possible causes
Before operation, open terminal box of motor to ascertain the corrective wirings.
Checking the winch for smooth operation by pressing up and down button of push
button switch. When winch fails to start after several attempts, or if any defective
operation to be happened, check followings:
Condition
Possible
Cause
.
Correction
No power
Check the input power source
Improper voltage or cycle
Check with motor markings
Wrong wirings
Check the wirings of motor and of switch
Defective brake coil or
bridge rectifier Check those according to its value
Defective centrifugal
switch, starting, switch. Check those parts
Fail to start
Over
-
load
Reduce load
Over
-
load
Reduce load
It can provoke non-opening of brake.
Relocate power so
urce
Longer lead shall be shorted
Fall to lift load
Considerable voltage drop
Improper section shall be corrected or
used a magnetic switch
Defective brake coil Check brake coil
Brake disc wear Replace brake disc
Conductor disc wear Replace conductor disc
Weak brake spring Replace brake spring
Considerable voltage drop Same as the above
Braking distance
unsatisfied
Winch is mechanically
binding up
Remove and disassemble the winch for
repair
Wrong wiring of 1 phase
winch
Exchange the blue and brown wires of
switchReversing
operation Wrong wiring of 3 phase
winch
Exchange any two wires of motor
alternately
6-2. Standard value for capacitor, brake coil and bridre rectifier
Model Starting cap. Running cap. Brake coil Bridge rectifier
CWG-10077 40MFD 125VAC 50MFD 250VAC 63ΩDC110V CBR-061
CWG-10151 125MFD 250VAC 15MFD 440VAC X x
CWG-30075/30075B
x x 434ΩDC220V CBR-061
6-3. Standard value for AC Solenoid
Model Cycle CWG-10151 / CWG-30151
Red & gray wires 60Hz 26~30Ω
Red & yellow wires 50Hz 31~35Ω

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Ⅶ
ⅦⅦ
Ⅶ. Wiring Diagram

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Ⅷ
ⅧⅧ
Ⅷ. Replacement parts List
►CWG-10077

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►CWG-10151/30151

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►CWG-30075

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CWG01-2008-02-2000