d & b audiotechnik Z5455 Quick start guide

ZZ5455
AL Flying frame
Rigging manual 1.1 en

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General information
Z5455
AL Flying frame Rigging manual
Version: 1.1 en, 10/2019, D2746.EN .01
Copyright © 2019 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.
We recommend you to regularly check the d&b website for the
latest version of this document.
When reselling this product, hand over this document to the new
owner.
If you supply d&b products, please draw the attention of your
customers to this document. Enclose the relevant documents with
the systems. If you require additional documents for this purpose,
you can order them from d&b.
d&b audiotechnik GmbH & Co. KG
Eugen-Adolff-Straße 134, D-71522 Backnang, Germany
T [phone], F [phone]
[email protected], www.dbaudio.com

Contents
1 Z5455 AL Flying frame...................................................... 4
1.1 Safety........................................................................................... 4
1.1.1 Intended use............................................................................ 4
1.1.2 General safety......................................................................... 4
1.1.3 Load safety information........................................................... 4
1.2 Scope of supply.......................................................................... 5
2 A-Series rigging components.......................................... 6
2.1 Suspension options..................................................................... 6
2.2 Z5453 AL Hoist connector chain.............................................. 7
2.3 Secondary safety........................................................................ 7
2.3.1 Z5454 AL Safety chain.......................................................... 7
2.4 Locking pins................................................................................. 8
2.5 Ring cotter................................................................................... 9
2.6 Cabinet rigging mechanism..................................................... 10
2.6.1 Front link mechanism............................................................ 10
2.6.2 Splay link mechanism........................................................... 10
2.6.3 Setting the splay angle(s)..................................................... 11
3 Rigging/Derigging............................................................ 13
3.1 Preparing the setup.................................................................. 13
3.2 Order of assembly................................................................... 13
3.3 Hoisting and securing the array.............................................. 16
3.4 Derigging.................................................................................. 16
4 Care and maintenance.................................................... 17
4.1 Transport/storing...................................................................... 17
4.2 Visual and functional inspection.............................................. 17
5 Declarations......................................................................... 18
5.1 Manufacturer's declaration...................................................... 18
5.2 Disposal.................................................................................... 18
Contents
d&b Z5455
AL Flying frame Rigging manual 1.1 en 3

Z5455 AL Flying frame
1.1 Safety
1.1.1 Intended use
The Z5455 AL Flying frame must only be used in conjunction with
the d&b A-Series AL60/AL90 and ALi60/ALi90 cabinets, as
described in this manual.
A-Series vertical arrays and ArrayCalc
A vertical A-Series array can consist of up to four loudspeakers for
mobile and installed applications where the captive rigging
components and the normal mounting accessories are to be used.
For installed applications where more than four loudspeakers are
required in a vertical array, ArrayCalc allows the prediction of
arrays with up to six A-Series loudspeakers.
Note: Please note that arrays of more than 4 loudspeakers
can only be mounted using custom cabinets and custom-
designed mounting accessories and require the array to be
driven with ArrayProcessing. For these special applications,
please consult with your d&b sales partner.
1.1.2 General safety
Installation and setup should only be carried out by qualified and
authorized personnel observing the valid national Rules for the
Prevention of Accidents (RPA).
It is the responsibility of the person installing the assembly to ensure
that the suspension/fixing points are suitable for the intended use.
Always carry out a visual and functional inspection of the items
before use. In case there is any doubt as to the proper functioning
and safety of the items, these must be withdrawn from use
immediately.
Please also refer to Þ Chapter 4 "Care and maintenance"
on page 17 .
1.1.3 Load safety information
NOTICE!
The Z5455 AL Flying frame is designed to suspend a total of 4 x
AL60/AL90 or ALi60/ALi90 cabinets which corresponds to a total
system weight of 100 kg (220 lb) – SWL.
1 Z5455 AL Flying frame
d&b Z5455
AL Flying frame Rigging manual 1.1 en4

Z5455 AL Flying frame
1.2 Scope of supply
Please verify the shipment for completeness and proper condition
of the items.
Qty. d&b Code Description
1Z5455 d&b AL Flying frame [1]
Including:
1 Locking pin 5 x 35 mm [2]
4 1t shackle [3]
1 Z5454 AL Safety chain 1.4 t (WLL) [4]
1 D2746.EN .01 Z5455 Rigging manual
Weight (incl. all items) 10 kg / 22 lb
Z5455 AL Flying frame dimensions in mm [inch]
d&b Z5455
AL Flying frame Rigging manual 1.1 en 5

A-Series rigging components
In addition the Z5455 AL Flying frame is equipped with the
following items:
Pos. Description
[S] Two safety points in the tie bar for the attachment of the
Z5454 AL Safety chain (also refer to Þ Chapter 2.3
"Secondary safety" on page 7.
[C] Cable pick.
Instruction label providing vital safety and rigging
instructions.
2.1 Suspension options
The center bar of the Flying frame is equipped with a total of 28
holes to allow for the suspension of the array and the setting of
different vertical angles.
The holes are numbered in increments of five.
Single or dual pickpoint operation
The array can be suspended using one or two E6507 1t shackle(s)
and appropriate lifting devices or steel wire ropes.
In "Single pickpoint operation", the overall vertical aiming of
the entire array is defined by using a particular hole of the hole
index on the center bar.
The corresponding hole position is calculated using the d&b
ArrayCalc simulation software. For this purpose, ArrayCalc can be
downloaded at www.dbaudio.com
In "Dual pick point operation", the vertical aiming of the
entire array is set by trimming the respective lifting devices.
Z5147 Rota clamp option
Alternatively, the array can be suspended and horizontally aligned
from a single pickpoint using the d&b Z5147 Rota clamp. The
clamp allows the load to be attached to overhead bars or truss
with a tube diameter of up to 51 mm (2”).
Attachment
Choose the appropriate hole position on the center bar according
to the ArrayCalc calculation and attach the clamp
correspondingly.
Note: Please observe the relevant mounting instructions
which are enclosed with the clamp.
2 A-Series rigging components
d&b Z5455
AL Flying frame Rigging manual 1.1 en6

A-Series rigging components
2.2 Z5453 AL Hoist connector chain
The Z5453 AL Hoist connector chain is used to connect the lifting
motor(s) to the AL Flying frame using the 1 t shackle. Its length of
53 cm (21") allows enough space for the hang of most 2 t motor
chain containers and avoids any impact on the vertical balance of
the array when suspended from a single pickpoint.
Specification
Lifting chain (DIN EN 818) 2-leg, 6 mm
Grade 10
Nominal length incl. hook 534 mm (21")
Load rating 1.4 t (WLL)
2.3 Secondary safety
WARNING!
Potential risk of personal injury and/or
damage to material!
The secondary safety suspension must be independent of the
primary suspension points and capable of carrying the total system
weight.
The additional safety device must be mounted in a way that the
array is caught by the safety device without any drop and swing in
the event that the primary suspension fails.
The A-Series Flying frame is equipped with two safety points [S] in
the tie bar of the frame fitted with two 1 t shackles to accept the
d&b Z5454 AL Safety chain or an appropriate equivalent
according to the specifications given in the following chapter
Þ 2.3.1 " Z5454 AL Safety chain".
Assembly
1. Before attaching the safety device, ensure the two 1 t shackles
[3] are properly fitted to the frame's safety points [S] as
shown in the graphic opposite.
2. Attach the safety chain and ensure the chains are not twisted
and the hooks [H] are in the right direction as shown in the
graphic opposite.
2.3.1 Z5454 AL Safety chain
The Z5454 AL Safety chain is supplied with the Flying frame.
Specification
Lifting chain (DIN EN 818) 2-leg, 6 mm
Grade 10
Nominal length per leg incl. hooks 534 mm (21")
Load rating 1.4 t (WLL)
d&b Z5455
AL Flying frame Rigging manual 1.1 en 7

A-Series rigging components
2.4 Locking pins
WARNING!
Potential risk of personal injury and/or
damage to material!
The steel wires of the Locking pins are not intended to carry any
load. The cabinet's weight must only be carried by the Front and
Splay/Rear links in conjunction with the front and rear rigging
strands of the loudspeaker cabinets and the rigging components.
Ensure all Locking pins are fully inserted and securely locked
before lifting any load.
The A-Series loudspeaker cabinets and rigging components are
equipped with a Locking pin 5 x 35 mm.
Note: The Locking pins are undetachably attached to the
different rigging components on the cabinet using steel wires.
Throughout this manual these steel wires are not shown in the
corresponding illustrations.
Functionality (Quick lock mechanism)
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. Insert the Locking pin through the respective link or socket until
it is fixed in place.
4. Release the button to lock the pin ( [l]).
5. Recheck the Locking pin is securely locked by briefly pulling
the Locking pin towards you.
d&b Z5455
AL Flying frame Rigging manual 1.1 en8

A-Series rigging components
2.5 Ring cotter
In connection with the A-Series rigging system, ring cotters are used
for the following items to prevent the respective item from
slackening and/or loosening:
▪ Fixing bolt of the shackles attached to the Flying frame.
▪ Fixing bolt of the cabinet's splay link.
▪ Fixing bolt of the Z5147 Rota clamp.
Function of the ring cotter
By default, the ring cotters are "locked" to prevent them from
loosening.
For modification reasons such as altering the position of the
Frame's Rear link or exchanging a shackle, it may be necessary to
temporarily remove the ring cotter and reattach it afterwards.
For this purpose proceed as follows:
1. Unlock
Unlock the ring cotter by pushing up the front wire loop over
the straight wire shaft.
2. Release and remove
Push down the rear wire loop until the ring cotter snaps over
the edge of the bolt and remove the ring cotter.
3. Refit and lock
Refit the ring cotter by pushing the straight wire shaft through
the hole and pressing the front wire loop underneath the
straight wire shaft.
Ring cotter
Ring cotter locked
d&b Z5455
AL Flying frame Rigging manual 1.1 en 9

A-Series rigging components
2.6 Cabinet rigging mechanism
The cabinets are mechanically connected to the Flying frame and
subsequent loudspeakers using the Front links on both sides of the
cabinet front and the central Splay link on the rear rigging strand
of the cabinet.
All necessary rigging components are mounted to the cabinet and
slide out or fold out when needed.
2.6.1 Front link mechanism
To extend and/or park the Front link, proceed as follows:
1. Slide out the Front link [1] up to its stop position.
↳Once the Front link is fully extended, it will be automatically
fixed in place by the spring steel sheet [2].
2. To slide the Front link back into its park position, press the
spring steel sheet towards the front grill.
3. Slide the Front link back into its park position.
2.6.2 Splay link mechanism
The Splay link is fixed in its park position ( ) by a Locking pin.
1. Release the Locking pin and fold out the Splay link.
2. To park the Splay link, proceed in reverse order and ensure
the extension tube is fully pushed in and the head is aligned
correspondingly, as shown in the graphic opposite.
d&b Z5455
AL Flying frame Rigging manual 1.1 en10

A-Series rigging components
2.6.3 Setting the splay angle(s)
Splay angles between adjacent cabinets can be set in the range
from 20° to 40° in 5° increments resulting in a total coverage of
50° up to 70° for two cabinets, with a maximum total coverage of
150° for four cabinets.
Splay angles can also be set symmetrically or asymmetrically,
depending on the application.
For this purpose, the Splay link provides two different lengths:
Standard or Extended.
Together with the corresponding Hole grid on the rear rigging
strand, the desired splay angles can be set in the range from 20°
to 40° in 5° increments.
The Splay link is constructed as a cylindrical extender (we call it
the 'Trombone';).
The extension tube head can be turned counter clockwise by 90°
and back again.
To change between the Standard and Extended positions, proceed
as follows:
Standard length
1. Fold out the Splay link as previously described.
2. Turn the extension tube head counter clockwise by 90° to fix
the standard length of the Splay link.
Extended length
1. Fold out the Splay link as previously described.
2. Pull out the extension tube to its stop position.
3. Turn the extension tube head counter clockwise by 90° to fix
the extended length of the Splay link.
Standard | Extended | Hole grid
Splay link lengths and correlation to the hole grid on the rear rigging strand.
d&b Z5455
AL Flying frame Rigging manual 1.1 en 11

A-Series rigging components
Overview chart - Splay angle settings
d&b Z5455
AL Flying frame Rigging manual 1.1 en12

Rigging/Derigging
3.1 Preparing the setup
General
Check the acoustical and mechanical setup using ArrayCalc and
prepare enough printouts for each array. Alternatively the d&b
ArrayCalc Viewer app can be used for this purpose.
The plan enables the riggers to set up the suspension points, the
securing points and the chain hoists.
When on site first:
▪ Clear the working areas and ensure there is enough space to
set up and lift the array.
▪ Check that the hoists are exactly in the specified position.
▪ Ensure the chains are not twisted.
▪ Prepare the cables and link cables according to the number of
amplifier channels and cabinets used.
Inspections before setup
Before setting up the array, carry out a visual inspection of all
system components for faults. This also includes the loudspeakers
and in particular the rigging parts of the cabinets (Front and
Splay/Rear links).
Damaged components must be withdrawn from use immediately.
Please also follow the instructions given in Þ Chapter 4 "Care and
maintenance" on page 17.
3.2 Order of assembly
Due to the compact size of the A-Series cabinets and the maximum
number of four cabinets that can be flown, the assembly may be
carried out either suspended or on the ground. The following
procedure refers to the suspended assembly.
1. Prepare the first cabinet
1. Extend both Front links.
2. At the rear, release the Locking pin of the Splay link.
3. Fold out the Splay link.
4. Pull out the link to the "Extended" length and turn the extension
tube head counter clockwise by 90°.
3 Rigging/Derigging
d&b Z5455
AL Flying frame Rigging manual 1.1 en 13

Rigging/Derigging
2. Attach the Flying frame
1. Attach the Flying frame on top of the cabinet until the Front
links of the cabinet fit into the slots at the front of the frame, as
shown in the graphic opposite.
2. Lift the back of the Flying frame until the Front links are
engaged.
3. Release the Locking pin of the Flying frame.
4. Insert the cabinet's Splay link into the slot of the Flying frame.
5. Insert the Locking pin and ensure the pin is fully inserted and
properly locked.
3. Prepare the next cabinet
1. Extend both Front links.
2. At the rear, release the Locking pin of the Splay link.
3. Fold out the Splay link.
4. Set the link to the required length (Standard or Extended) and
turn the extension tube head counter clockwise by 90°.
d&b Z5455
AL Flying frame Rigging manual 1.1 en14

Rigging/Derigging
4. Attach the prepared cabinet
1. Suspend the assembly according to the desired suspension
option.
2. Lift the assembly to a suitable working height.
3. With one person on each side, attach the prepared cabinet at
an angle of approx. 90° to the corresponding slots at the
front of the upper cabinet, as shown in the graphic opposite.
4. Slightly lower the cabinet until the Front links are engaged.
5. On the rear rigging strand, release the corresponding Locking
pins on the top and bottom cabinets.
d&b Z5455
AL Flying frame Rigging manual 1.1 en 15

Rigging/Derigging
6. Raise the back of the bottom cabinet.
7. Align the prepared Splay link with the corresponding hole of
the rear rigging strand of the upper cabinet.
8. Insert the Locking pins and ensure the pins are fully inserted
and properly locked.
To add further cabinets, proceed in the same manner until the
assembly is completed.
5. Rig the cabling
Connect the flying cables and link cables according to the number
of amplifier channels and cabinets used. Observe the related
loudspeaker setups for the inner (In) and outer (Out) cabinets.
6. Check the assembly
Before hoisting the array to its operating position, recheck the
entire assembly.
3.3 Hoisting and securing the array
When all the mechanical adjustments, system checks, and safety
checks have been made, the array can be hoisted up to its
operating position.
When hoisting the array, ensure that the loudspeaker cables do
not get caught anywhere. The cables can be strapped together
with the motor cable to form a loom while the system is hoisted.
The chain hoist motors must raise the system slowly and evenly so
that it does not swing or move from side to side during hoisting.
When the array is in its final operating position, the secondary
safety device must be attached (please also refer to
Þ Chapter 2.3 "Secondary safety" on page 7).
3.4 Derigging
To dismantle any of the assemblies, follow the corresponding
rigging and setup instructions in reverse order.
The same safety instructions apply!
d&b Z5455
AL Flying frame Rigging manual 1.1 en16

Care and maintenance
4.1 Transport/storing
During transport ensure the rigging components are not stressed or
damaged by mechanical forces. Use suitable transport cases.
We recommend the use of the d&b E7927 Touring case 2 x AL for
this purpose. The touring case provides specific trays and fixtures
for the AL Flying frame and AL Flying adapter.
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.
4.2 Visual and functional inspection
WARNING!
Potential risk of personal injury and/or
damage to material
To eliminate the potential risk of accident due to malfunctioning of
a component, regularly inspect all system components.
Cabinet enclosure
▪ Visual inspection of all fitting plates for obvious damage (e.g.
cracks or corrosion).
▪ Visual inspection of the rear rigging strand for obvious damage
(e.g. cracks, deformation or corrosion) including all drilled holes
of the component.
▪ Inspection of all fitting plates including front grills to ensure they
are securely attached.
▪ Regularly lubricate the sockets using WD-40® or a similar
product.
Front and Splay links
Visual inspection regarding deformation and damage (e.g. cracks
and corrosion) including all drilled holes of the component.
Locking pins
▪ Visual inspection for deformation, cracks and corrosion of the
component.
▪ Inspection for missing ball bearings and damage.
▪ Functional inspection of the release mechanism to ensure it
operates properly.
▪ Regularly lubricate the Locking pins using WD-40® or a similar
product.
Z5455 AL Flying frame
Visual inspection regarding deformation and damage (e.g. cracks
and corrosion) including all drilled holes of the component.
E7927 Touring case 2 x AL
4 Care and maintenance
d&b Z5455
AL Flying frame Rigging manual 1.1 en 17

Declarations
5.1 Manufacturer's declaration
This declaration covers:
▪ d&b Z5455 AL Flying frame.
National standards and technical specifications
applied:
DIN 18 800, DIN 1055, DGUV Vorschrift 17.
Backnang, 2019-08-12
Frank Bothe,
Chief Technology Officer (CTO)
d&b audiotechnik GmbH & Co. KG
5.2 Disposal
When out of use the rigging components must be disposed of in
accordance with the national environmental regulations.
Ensure that damaged rigging components are disposed of in a
way that they cannot be used again.
5 Declarations
d&b Z5455
AL Flying frame Rigging manual 1.1 en18

D2746.EN .01, 10/2019 © d&b audiotechnik GmbH & Co. KG
www.dbaudio.com