d & b audiotechnik Z5080 User manual

Z5080
Flying bar
Mounting instructions

WARNING!
IMPORTANT!
CAUTION!
General Information
Mounting instructions
Z5080 Flying bar
Version 3.0E, 10/1999, D0016901
opyright d&b audiotechnik AG 1999; all rights reserved.
The information presented in this document is, to the best of our
knowledge, correct. We will however not be held responsible for
the consequences of any errors or omissions. Technical
specifications, weights and dimensions can change and should
always be confirmed with d&b audiotechnik AG prior to inclusion
in any additional documentation.
d&b audiotechnik AG
Eugen-Adolff-Strasse 134, D-71522 Backnang
Telephone [phone], Fax [phone]
Z5080 Flying bar
References in the manual
This refers to a potentially dan-
gerous situation which may lead
to personal in ury.
This refers to a potentially danger-
ous situation which may lead to
equipment damage.
This refers to a situation which may
cause the equipment to mal-
function.
Symbols on the equipment
Please refer to the information in
the operating manual.

(2.0 E) 3-8
WARNING!
WARNING!
General Safety and Installation Advice
General safety advice
d&b loudspeakers should only ever be flown or installed using
recommended d&b rigging accessories. The d&b rigging accessories
described in the d&b rigging accessories manual and the specific
mounting instructions are designed and manufactured to have a
high load safety factor for their intended role. In order to ensure
the highest safety standards, the information presented here on the
assembly and safe use of d&b rigging accessories must be carefully
understood and followed.
The installation of d&b loudspeakers using the rigging accessories
described in the d&b rigging accessories manual and the specific
mounting instructions should only ever be carried out by properly
qualified personnel in full compliance with all required safety codes
and safety standards in force at the place of installation.
(In Germany, this means compliance with the recommendations of
BGV C1 GUV .15)
d&b rigging accessories (components and assemblies) are supplied
exclusively for use with specific d&b loudspeakers and are not
designed or intended for use with any other loudspeakers or any
other devices. The use of d&b rigging accessories to deploy
loudspeakers and devices other than those indicated in the d&b
rigging accessories manual and the specific mounting instructions is
improper use. Improper use can compromise safety by overloading
and damaging the rigging accessories. d&b will not be held
responsible for any damage or injury resulting directly or indirectly
from the improper use of d&b rigging accessories.
d&b rigging accessories must not be modified in any way nor should
they be assembled in ways other than those indicated in the d&b
rigging accessories manual and the specific mounting instructions.
Rigging components supplied as part of a complete assembly are
non-interchangeable and must not be exchanged with the
component parts of any other assembly.
The component parts of a d&b rigging accessory must only be
assembled using the fasteners and methods of assembly
recommended in the d&b rigging accessories manual and the
specific mounting instructions. The use of fasteners and methods of
assembly not specified or approved by d&b may result in an unsafe
rigging assembly. Welding, or any other means of permanently
fixing rigging components to each other or to cabinet fixing points is
not allowed.
General installation advice
Only the screws, fasteners, plain and shakeproof washers specified
on the relevant page(s) of the d&b rigging accessories manual and
the specific mounting instructions shall be used to fasten together,
where appropriate, suitable d&b rigging components.
d&b rigging components or assemblies must only be fixed to d&b
loudspeaker cabinets using the cabinet fixing points, assembly
methods and fasteners specified on the relevant page(s) of the d&b
rigging accessories manual and the specific mounting instructions.
Any wall, floor or ceiling to which a d&b loudspeaker is fixed or

4-8 General safety and mounting instructions
WARNING!
WARNING!
WARNING!
attached using a d&b rigging accessory must be capable of safely
and securely supporting the actual load. The rigging accessory used
must be safely and securely fixed both to the loudspeaker and to
the wall, floor or ceiling.
Other points to consider are: When mounting rigging components
on walls, floors or ceilings ensure that all fixings and fasteners used
are of an appropriate size and load rating (DIN 18800 standards
apply within Germany). Wall and ceiling claddings and the
construction and composition of walls and ceilings all need to be
taken into account when determining whether a particular fixing
arrangement can be safely employed for a particular load. Cavity
plugs or other specialist fixings, if required, must be of an
appropriate type, fitted and used in accordance with the makers
instructions.
Use only the rigging accessory fixing holes indicated on the relevant
page(s) of the d&b rigging accessories manual and the specific
mounting instructions to fix d&b rigging accessories to walls, floors
or ceilings. Where specified, the recommended maximum torque
settings for screw fasteners must be strictly complied with.
Secondary safeties
All loudspeakers flown in theatres, studios or other places of work
and entertainment must, in addition to the principle load bearing
means of suspension, be provided with an independent, properly
rated and securely attached secondary safety.
Only steel wire ropes or steel chains of an approved construction
and load rating may be used as secondary safeties. Plastic covered
steel wire ropes are not permitted for use as secondary safeties. As
recommended by BGV C1 (GUV .15), the secondary safety must
prevent the load from dropping more than 20 cm if the principal
means of suspension fails.
Safety inspections
All rigging components and assemblies are subject to wear and
tear, aging, corrosion etc. As safety critical components, its
imperative that, prior to each and every use or installation, all
rigging components, rigging assemblies and cabinet fixing points
are carefully inspected to ensure that they are free of defects and
that they function flawlessly. Care should be taken to identify signs
of undue wear and tear, dents, cuts, tears, splits and any
indications of corrosion. If upon inspection, damage is discovered
and there exists even the slightest doubt as to the physical integrity
and safety of the damaged item, then the damaged item must not,
under any circumstances, be deployed.
Regular, more rigorous test and inspection of rigging components
must also be carried out. Safety legislation and test and inspection
requirements will vary from country to country. In most cases,
annual independent test and inspection by a suitably approved and
qualified inspector will be required - users must ensure compliance
with all applicable safety requirements.
d&b recommends regular safety inspections and further
recommends that a logbook be kept detailing the test and inspection
history of each d&b rigging accessory.

(2.0 E) 5-8
Load safety factors
Rigging accessories are safety critical components which can, by
their failure, lead to injury or death. To maximise safety and to
reduce the risk of the possible consequences of failure, there exist
various recommendations which attempt to govern the safe design
and construction of rigging components. Unfortunately, such
recommendations vary from country to country and are frequently
adaptations of building or construction safety codes which were
never intended to specifically cover loudspeaker rigging.
A further complicating factor, frequently a result of insurance
requirements, is that different load safety factors may be demanded
for different applications. For example, the load safety factor of a
rigging component suitable for a fixed, static application may be
regarded as insufficient for a mobile application.
What exactly is a load safety factor?
It is accepted general engineering practice to design and build
components to have a minimum 1.25X load safety factor. That
means a component or assembly that can resist without breaking, a
load 25% greater than its specified safe working load (SWL).
Load safety factors are tailored to the estimated level of risk
presented by a particular application - the higher the estimated
level of risk, then the higher the load safety factor demanded.
Because of the high level of risk associated with the possible failure
of rigging, load safety factors much greater than 1.25X are
demanded. The EU Machinery Directive for example, specifies a 4X
load safety factor for shackles. This means that a shackle specified
for a SWL of 500 kg should be able to resist a 2000 kg load without
breaking.
Even more stringent load safety factors than those specified under
EU legislation can apply to applications where rigging is used. One
of the most demanding safety codes, the one used to derive the
high load safety factors for d&b rigging accessories, is the German
BGV C1 safety code.
Section §9 of Unfallverhütungsvorschrift Veranstaltungs- und
Produktionsstätten für szenische Darstellung (BGV C1 GUV .15)
draws a distinction between components used to rig a fixed, static
load and components used to rig a moving load. Different load
safety factors are required for otherwise similar components
depending upon whether they are used with a fixed or with a
moving load. A higher load safety factor being required for rigging
subject to the higher stress of dynamic loading.
The recommendations are met if it can be shown that:
The SWL of components such as ropes and slings used as
rigging for a fixed load does not exceed 1/10 of their
calculated ultimate stress
and
The SWL of components such as ropes and slings used as
rigging for a moving load does not exceed 1/12 of their
calculated ultimate stress ...

6-8 General safety and mounting instructions
WARNING!
Rigging component
Safety factors
Steel wire ropes
factor 5 (EN292-2, chpt. 4.1.2.5a)
Welded link chains
factor 4 (EN292-2, chpt. 4.1.2.5 )
Fa ric slings
factor 7 (EN292-2, chpt. 4.1.2.5c)
Metal components
factor 4 (EN292-2, chpt. 4.1.2.5d)
A 12X load safety factor is therefore recommended for the
following components:
•
Chains
•
Steel wire ropes (for lifting and securing)
•
Shackles
•
Eyebolts etc.
In contrast, the EU Machinery Directive (EN292-2) specifies the
following load safety factors for rigging components:
The regulations enshrined in the EU directive are general
regulations - few in number and not always particularly clear or
detailed. Loudspeakers and their rigging components are not
specifically covered. The electrical and mechanical standards of
construction for lanterns are covered by a DIN standard (DIN
155 0). However, there is no specific DIN or Euro standard
covering standards of construction for loudspeaker rigging
components or assemblies.
To make matters clear, at least as far as d&b rigging accessories
are concerned, we have adopted the following load safety factors:
12X load safety factor:
Chains, ropes, shackles, eyebolts, straps and hooks.
10X load safety factor:
Accessories and fixings for mobile use.
5X load safety factor:
Accessories generally employed in fixed, permanent installations.
The 12X load safety factor is derived from §9, GUV .15
The 10X load safety factor is likewise derived from §9 GUV .15. as
a basic safety standard for rigging components.
From EN292-2 chpt. 4.1.2.5d a 4X minimum load safety factor can
be derived for all metal rigging components used in fixed
installations. Our choice of a 5X minimum load safety factor for
such components provides an enhanced safety margin.
ttaching rigging to loudspeaker cabinets
d&b rigging accessories are supplied with specific mounting
instructions and must only be assembled and used in the manner
described in these instructions or as specified on the relevant
page(s) of the d&b rigging accessories manual. Failure to fully
observe specified load capacities or fitting instructions can
overload the rigging accessories or the loudspeaker cabinet fixing
points causing them to break.
The d&b rigging accessories described in the d&b rigging
accessories manual and specific mounting instructions are directly

(2.0 E) 7-8
WARNING!
attached to d&b loudspeaker cabinets and are secured using either
screws or bolts fastened to threaded inserts fitted in the
loudspeaker cabinets. For attaching rigging, d&b loudspeaker
cabinets are fitted threaded inserts.
Where provided, the supplied screws or bolts should be used to
attach rigging. Using screws or bolts other than those supplied or
specified can result in an insecure and unsafe fixing. Additionally,
using screws or bolts longer than those supplied or specified can
physically damage a cabinet by penetrating its interior and causing
an air leak.
Load ratings
d&b rigging accessories are designed and constructed to have a
load rating appropriate to their intended use. The safe working
load (SWL) for each d&b rigging accessory is specified in its
respective data sheet and on the relevant page(s) of the d&b
rigging accessories manual.
In general, d&b rigging components are designed with a 10X load
safety factor. Some components, specifically intended only for use
in fixed, permanent installations are designed with a 5X load safety
factor. Other components, for use with moving as opposed to static
loads and therefore subject to the additional wear of dynamic
loading, are designed to have a 12X safety factor.
Safety certificates
In Germany, the health and safety authority together with
industrial and professional associations has published a safety code
for stages and studios. Sound reinforcement equipment installed in
these places has to comply with the provisions of this code,
published as BGV C1 (GUV .15) Unfallverhütungsvorschrift
Veranstaltungs- und Produktionsstätten für szenische Darstellung.
The code provisions include:
1. Plastic load bearing components are not permitted.
2. Plastic laminated or coated steel wire ropes are not permitted.
3. Load connector parts must have a load safety factor 10X
greater than their stated SWL (Safe Working Load).
4. Load bearing chains must have a load safety factor 0.5X
greater than the dynamic value specified by the manufacturer
- equivalent to a load safety factor 12X the specified SWL.
Provision #4 needs some explanation. High tensile chains and
related components conforming to EN 818, grade 8 are specified
with a load safety factor 4X their SWL. To comply with the 12X
load safety factor required for load bearing chains under BGV C1
(GUV .15), the specified SWL for DIN certified chains must be
derated by a factor of three.

Flying bar and Flying bar chainset.
Delta link (E6511) and Shackle used to
attach Ratchet strap (E6510) to the Flying
bar
(3.0E) Z5080
Z5080 Flying bar
The Z5080 Flying bar allows two vertical columns of C4 or F2/B1
loudspeakers to be flown - both columns consisting of the same
loudspeaker cabinets.
The angle between the columns rows is preset to 30° for C4
loudspeakers and to 40° for F2/B1 systems. The resulting combined
horizontal coverages are 70° (C4-TOP) and 100° (F2 loudspeaker).
Its also possible to set a 0° horizontal angle for use with
subwoofers.
Typical applications are:
Fixed installations using C4 and F2/B1 systems
Flown front-of-house system for small and medium-sized venues
Delay clusters for larger venues and systems
Supplementing the C4 Flying system, e.g. for a 2-wide F2 or
C4 side fill for a 4-wide C4 main FOH system
Monitor side-fills on larger stages
The Flying bar is manufactured for d&b by UK specialist MAN Flying
Systems. It is made of powder-coated U-section steel with suspension
eyelets. A matching Z5081 Flying bar chainset is also available. The
Flying bar is 152 cm wide. The vertical distance from the suspension
point to the fixing plane of the load chains is 63 cm. The Flying bar
weighs 45 kg and the chainset 6.5 kg.
Assembly
For use with the Flying bar chainset, two pairs of fixing lugs are
provided, equidistantly spaced each side of the centre point of the
bar. The four chains of the chainset are captively fitted at one end to
an O ring used to suspend the bar and its speaker load from a
central flying point. The free ends of the chains are attached to bar
fixing lugs using 2 tonne shackles.
The loudspeaker columns are vertically suspended from the bar in
the same manner as the C4/C7/F2/B1 Flying system using 1 tonne
steel rigging chains, MAN Flying studs and 5t Ratchet straps. The
assembly and use of these components is more fully described under
C4/C7/F2/B1/MAX Rigging accessories.
The Flying bar also includes central fixing lugs for Ratchet straps
between the chain fixing points for each of the two suspended
loudspeaker columns. Each Ratchet strap attaches to its fixing point
using a 1t Shackle and Delta link.
For parallel loudspeaker columns, all the load rigging chains attach
to the U section of the Flying bar using Shackles. The fixing points for
the Ratchet straps remain the same when the chain fixing points for
angled loudspeaker columns are used. The Flying bar chainset is now
attached to two fixing points on the outer edges of the bar and at
two additional points at the centre of the U section of the Flying bar.

d&b audiotechnik AG, Eugen-Adolff-Str. 134, D-71522 Backnang, Germany, Phone [phone], Fax [phone]
WARNING!
Flying bar with C4 system
Load safety information
The maximum permissible load including the loudspeakers and
rigging hardware is 500 kg.
Distribute the load symmetrically around the centre of
the Flying bar since, unlike the Flying system for C4/
C7/F2/B1/MAX, it is not possible to adjust the bar
balance for unequal loads.
Secondary safeties must always be provided and used when flying
loudspeaker loads.
The load capability stated above allows the following systems to be
deployed:
8 x C4-TOPs or SUBs
4 x F2s or B1s (old version with flying eyes)
4 x F2 loudspeakers + 2 x B1-SUBs (new version with MAN studs)
Each Flying bar is individually tested to twice its rated load.

d&b audiotechnik AG, Eugen-Adolff-Str. 134, D-71522 Backnang, Germany, Phone [phone], Fax [phone]
Declaration of Conformity to BGV C1
This declaration applies to the following components described in this Rigging
Accessories Manual :
Z5024 Loudspeaker stand adapter
Z5010 TV spigot with fixing plate (shipped after 27/11/97)
Z5012 Pipe clamp for TV spigot
Z0127 T bar adapter
Z5020 02 Flying adapter
Z5025 03 Flying adapter
Z5015 02 TV spigot
Z5021 02 Flying frame, 90° (shipped after 12/2/98)
Z5022 02 Flying frame, 60° (shipped after 3/4/98)
Z5023 02 Flying bracket (shipped after 27/8/97)
Rigging accessories C4/C7/F2/B1/MAX
Z5042 Flying plate
Z5080 Flying bar
Z5090 Single bar
Z5016 Heavy duty Pipe clamp
Z5017 Heavy duty TV spigot
Z0124 E1 Vertical bracket
Z0126 E1 Horizontal bracket
Z5033 E3 Ball joint adapter
Z5029 TV spigot for E3 ball joint adapter
Z5027 E3 Ball joint wall bracket
Z5031 E3 Standard bracket
Z5030 E3 x 2 Angle bracket
Z5032 E3 Swivel bracket
Z5028 E3 Horizontal bracket
Z5007 1220 Frame
Z5008 1220 Stand adapter
Z5043 MAX Horizontal bracket
Z5044 MAX Bracket connector
We hereby declare that the above listed products supplied by
d&b audiotechnik AG comply with the relevant requirements of
BGV C1(GUV 6.15).
d&b audiotechnik AG of Backnang accepts responsibility for
this declaration.