ETC Vortek NXT User manual

Part Number: 8070M2100 Rev: B
Released: 2018-12
Vortek NXT Hoist
Installation and Operations
Manual

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ETC intends this document, whether printed or electronic, to be provided in its entirety.

Table of Contents i
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Help from ETC Technical Services . . . . . . . . . . . . . . . . . . . . . . .2
Acronyms and Definition of Terms. . . . . . . . . . . 3
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Information of Vortek NXT Hoist . . . . . . . . . . . . . . . . .4
DO’s and DON'Ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hoist Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Technical Description . . . . . . . . . . . . . . . . . . . . . 7
Vortek NXT Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Incoming Goods, Transport and Storage . . . . . . . . . . . . . . . . .7
General Information for Storage . . . . . . . . . . . . . . . . . . . . . . .9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Information on Installation . . . . . . . . . . . . . . . . . . .10
Uncrating Vortek NXT Hoist . . . . . . . . . . . . . . . . . . . . . . . . . .11
Basic Hoist Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Attaching Backbone Stiffeners. . . . . . . . . . . . . . . . . . . . . . . .12
Mounting Vortek NXT Hoist . . . . . . . . . . . . . . . . . . . . . . . . . .14
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Vertical Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
System Setup and Test. . . . . . . . . . . . . . . . . . . .23
Verify Proper Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Verify Hoist Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Test System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Set Upper and Lower Limits . . . . . . . . . . . . . . . . . . . . . . . . . .25

ii Vortek NXT Hoist Installation Manual
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 28
Service and Maintenance . . . . . . . . . . . . . . . . .29
General Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Annual Inspection and Maintenance Checklist . . . . . . . . . . .29
Materials Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Motor Gearbox Inspection and Maintenance Instructions . .30
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Introduction 1
Introduction
Welcome to the Vortek NXT Hoist Installation and Operations Manual. This manual will guide
you through the operation, installation, and maintenance of the Vortek NXT hoist.
Document Conventions
This document uses the following conventions to draw your attention to important
information.
ETC's user documents are designed for printed or electronic use. However, there are many
advantages to using the electronic (.PDF) versions. In addition to the benefits of a PDF (such
as word search, bookmarks, and commenting tools) you can click on headings in the Table of
Contents and jump to the desired page. Throughout this document, any cross-references
(indicated in blue italics like this:
Introduction on page 1 ) are links that may be clicked to jump
to the specific part of the manual.
All of ETC's documents are available for free download from our website:
www.etcconnect.com.
Please email comments about this manual to: [email protected].
Note:
Notes are helpful hints and information that is supplemental to the main text.
CAUTION:
A Caution statement indicates situations where there may be undefined or
unwanted consequences of an action, potential for data loss or an equipment
problem.
WARNING: A Warning statement indicates situations where damage may occur, people
may be harmed, or there are serious or dangerous consequences of an action.
WARNING: RISK OF ELECTRIC SHOCK! This warning statement indicates situations where
there is a risk of electric shock.

2Vortek NXT Hoist Installation Manual
Help from ETC Technical Services
If you are having difficulties, your most convenient resources are the references given in this
document. To search more widely, try the ETC website at www.etcconnect.com. If none of
these resources are sufficient, contact ETC Technical Services directly at one of the offices
identified below. Emergency service is available from all ETC offices outside of normal
business hours.
When calling for help, please have the following information available:
• Detailed description of the problem
• Be near the equipment for troubleshooting
• Notification number if you have called in previously
Americas United Kingdom
Electronic Theatre Controls Inc. Electronic Theatre Controls Ltd.
Technical Services Department Technical Services Department
3031 Pleasant View Road 26-28 Victoria Industrial Estate
Middleton, WI 53562 Victoria Road,
800-775-4382 (USA, toll-free) London W3 6UU England
[phone] [phone]
[email protected] s[email protected]
Asia Germany
Electronic Theatre Controls Asia, Ltd. Electronic Theatre Controls GmbH
Technical Services Department Technical Services Department
Room 1801, 18/F Ohmstrasse 3
Tower 1, Phase 1 Enterprise Square 83607 Holzkirchen, Germany
9 Sheung Yuet Road [phone]
Kowloon Bay, Kowloon, Hong Kong [email protected]
[phone]
[email protected]

Acronyms and Definition of Terms 3
Acronyms and Definition of Terms
The following are acronyms and definition of terms used throughout this manual.
• Acme Screw - A leadscrew that translates the hoist drum, motor, and gearbox.
• Competent Person - Person who has such practical and theoretical knowledge and such
experience as is necessary to carry out the work and is aware of the limits of his/her own
competence, expertise and knowledge.
• Control System - ETC control equipment associated with the operation of the hoist or hoist
system.
• Hazard - Potential source of harm.
• Hoist Capacity - Maximum load capacity applied to a hoist or hoist system. This includes all
attached components and accessories in the load path.
• Line Set - The combination of a hoist, load-bearing equipment and load-carrying device.
• Machinery Installation - The integration of load-bearing equipment, drive system, loadcarrying
devices and scenic elements.
• Point Load - A load that is localized to a specific location.
• Qualified Person - Person who, by possession of a recognized degree or certificate of professional
standing, or who by extensive knowledge, training and experience, has demonstrated the ability
to solve problems relating to the subject matter and work.
• Risk - Combination of the probability of occurrence of harm and the severity of the harm.
• Risk Assessment - The systematic examination of the machinery or electrical installation in order
to identify relevant hazards, estimate and evaluate related risks and put in place protective
measures to reduce the risk to an acceptable level.
• 3 Phase - Refers to a system of power distribution of 3 electric power conductors carrying
alternating current voltages whose cycles are offset by 120° from each other.
• Trained/Authorized Person - A person trained or authorized by ETC to perform work on the
Vortek hoist.
• Uniform Distributed Load (UDL) - A load that is constant over a certain distance.
• Working Load Limit (WLL) - The maximum load (mass) that the user can hang on the loadcarrying
device (e.g., batten, truss), provided it is a uniform distributed load.
Note:
The Working Load Limit is equal to the Hoist Capacity minus the weight of the load
securing and carrying devices.

4Vortek NXT Hoist Installation Manual
General Warnings
Safety Information of Vortek NXT Hoist
• All operators and maintenance personnel must be aware of the Emergency Stop buttons.
• In the event of an unexpected move, use the Emergency Stop button to bring all movement to
an immediate stop.
• Carry out a full risk assessment for your particular application.
DO’s and DON’Ts
• DO NOT operate a Vortek NXT hoist without having a clear view of the attached load and load
carrying device through the entire intended travel path or reliable communication with someone
who does.
• DO install the machine either in a protected area or accessible only to competent and qualified
persons.
• DO NOT remove 1/4” screws on the aluminum motor-gearbox and tail support frames. In
general, do not remove hardware from the hoist that is not identified in this manual.
All Warning notes contained in this manual provide information about potential hazards that
may endanger personnel.
WARNING: The voltages used in the motor control box can cause severe electrical shock
and/or burns.
Extreme care is necessary at all times when working with the motor control
box.
Only authorized personnel must carry out any installation, commissioning or
maintenance of the electrical systems.
All drive systems have been tuned at the factory and will not require any
additional alteration or adjustment by the owner’s personnel unless
specifically authorized by an ETC representative.
WARNING: Do not exceed point load, Uniform Distributed Load (UDL), or Working Load
Limit (WLL) or Hoist Capacity for any line set. ETC hoists must only be used to
move a maximum load equal to or less than the capacity of your specific hoist.
Overloading the hoist may result in damage to the system, other property
damage, serious injury, or death.
WARNING: ETC hoists and the controller equipment must not be operated by a user until
installation and configuration have been completed by an ETC trained/
authorized technician. Only ETC trained/authorized technicians are
authorized to operate equipment during the installation and configuration
process.
WARNING: This equipment is not designed to lift, move, fly, suspend, or automate
people or animals, and such use is strictly prohibited.

General Warnings 5
WARNING: Before working on any of the Vortek hoists, the main electrical disconnect
must be turned off and locked out.
WARNING: Machinery installation, maintenance and disposal must be performed by
competent or qualified persons.
WARNING: At the end of machinery installation, commissioning must be performed by a
qualified person.
WARNING: Do not run the system without all Emergency Stop switches/buttons
connected and in position.
WARNING: Do not start initial operations before a competent person or a trained
specialist has inspected the equipment.
WARNING: Do not use a Vortek NXT hoist without having performed the daily
inspection. See
General Checks on page 29 .
WARNING: Do not connect the Vortek NXT hoist electrical connection to any power
supply socket that has not been tested by a qualified individual.
WARNING: Do not connect a Vortek NXT hoist to a power source other than specified on
the unit and in this manual.
WARNING: Do not modify a Vortek NXT hoist in any way unless expressly told to do so by
the manufacturer.
WARNING: Do not modify the adjustments of the safety components and functionalities
outside the limits provided in this manual, or without the written
authorization of the manufacturer.
WARNING: Do not open the controller or remove the outer casing if the system is
connected to a power source, even if the Vortek NXT hoist itself is not
powered on. Doing so can result in damage to the product and is a health
hazard.

6Vortek NXT Hoist Installation Manual
Hoist Capacity
All hoists have a limited Hoist Capacity and all line sets have a Working Load Limit. The Hoist
Capacity is identified on the product label on the motor control box. The limits are not the
same for all line sets, so be sure to check the Working Load Limit for all line sets in your
system. NEVER exceed the working load limit or the Hoist Capacity for any line set.
Intended Use
A Vortek NXT hoist is a fixed- or variable-speed electric wire rope winch designed for use in
the entertainment and event industry (theatres, multi-purpose halls, exhibition halls,
television and radio studios, concert halls, schools and other rooms for shows and events).
It is designed to work with other ETC hoists, controlled by Foundation, QuickTouch Preset,
QuickTouch, and QuickTouch+ user interfaces.
This machine is not intended for use in potentially explosive atmospheres and/or in contact
with dangerous substances. This equipment is not intended to lift, move, fly, suspend or
automate people or animals, and such use is strictly prohibited.
Operating Environment
The Vortek hoist is designed for indoor use only and designed to work in ambient
temperatures between 0°C and 40°C (32°F and 104°F), 10-90% non-condensing humidity.
The Vortek hoist has an Ingress Protection (IP) rating of IP40.
Vortek hoist emission sound pressure level is below 70db at the operator’s position.
This guide assists with the most common ETC installations and scenarios showing basic
mechanical layouts.
Each installation will have its own layout and drawings as specified by the Architect and
Theatre Consultant that works best for the theatre involved.
Refer to the drawings for specific information that may be needed.
If any questions arise, please contact ETC at: 1-800-688-4116 or ETC authorized
representatives
WARNING: Do not enable the hold-to-run control button (up or down button) in any
other way than described in this manual. The hold-to-run control button
must always be under manual operator control.
WARNING: Do not use a Vortek NXT hoist if it does not appear to be in 100% perfect
working order.
WARNING: Do not distract the operator’s attention while they are operating the system.

Technical Description 7
Technical Description
Vortek NXT Specifications
The Vortek NXT hoist is designed to work with ETC hoists, controlled by Foundation, QuickTouch
Preset, QuickTouch, or QuickTouch+ controls.
A Vortek NXT hoist is a fixed- or variable-speed electric wire rope winch, designed for use in the
entertainment and event industry.
Incoming Goods, Transport and Storage
Unloading Vortek NXT Hoists
Each Vortek NXT hoist crate has a label that identifies hoist type and position and whether the crate
contains the project packet, project drawings, this manual, the Rigging System Commissioning Signoff
and Rigging System Training Signoff forms.
Each crated Vortek hoist weighs approximately 500 kg (1100 lbs.).
There are only two places where the Vortek crates can be lifted with a forklift, the side and the Motor
End.
The first lifting point is from the Motor End
A forklift that has fork tines that are at least 104 cm (41") long, a maximum of 22 cm (8-1/2”) wide
and 5 cm (2") thick is required to lift from the Motor End.
WARNING: Never lift the crate from the Tail End position. If lifting the crate by an end
position, only lift it from the Motor End (heaviest) position.
T
a
il
En
d
Ta
i
l
E
n
d
a
d
d
d
d
d
d
d
d
d

8Vortek NXT Hoist Installation Manual
Insert the forks completely into the slot and raise the forks and the rack to lift the crate.
The second lifting point is from the side
Note:
When using this location, spread the forks as wide as possible; either side can be
used to lift the crates.
M
OT
O
R
E
N
D
M
OT
O
R
E
N
D
TAIL
E
N
D
TAIL
E
N
D

Technical Description 9
Each motor end of the Vortek NXT crate will be labeled with the model number and/or line set number.
Organizing the hoists as they are unloaded may help during installation.
Follow the layout plan in order to place the crates in the right position.
The layout, nameplate, and label on the side of the crate identify the model number and placement
within the installation.
Once out of the crate, Vortek NXT hoists are virtually indistinguishable from each other except for the
label on bottom of the Motor Control Box (MCB)
General Information for Storage
Vortek NXT hoists are designed for indoor use only and must be stored in a cool, dry location in
temperature range between -4°F (-20°C) and 140°F (60°C) at 10-90% non-condensing humidity. If the
hoist has been exposed to drastic temperature fluctuations (i.e. during transport), do not connect it to
a power source immediately.
The change of temperatures can cause condensation to form on both exterior casings and interior
parts which can damage the hoist if powered on.
Leave the Vortek NXT hoist disconnected from a power source until it has equalized with the
temperature in the location it is to be installed.
CAUTION:
The Vortek hoists are not balanced at center, so care must be taken when
moving the units.
Note:
Each ETC Rigging project has a detailed set of job drawings which determine the
installation location of each hoist and the related equipment. Refer to these
drawings for system layout, lift line layout, and location.

10 Vortek NXT Hoist Installation Manual
Installation
General Information on Installation
Vortek NXT Hoist Installation Tool List
A non-metric tool set is required for the Vortek NXT hoist installation.
• 9/16” Combination Wrench
• 3/4” Combination Wrench
• 3/8” Drive 7/16” Socket
• 3/8” Drive 1/2” Socket
• 3/8” Drive 9/16” Deep Well Socket
• 1/2” Drive 3/4” Deep Well Socket
• 3/8” Drive Torque Wrench
• 3/8” Drive Ratchet
• 1/2” Drive Ratchet
• 18" Long 3/8” Drive “Wobble” Extension or Universal
• 1/4” Allen Wrench
• 3/32” Allen Wrench
• 10 mm socket
• Cordless Drill with 3/8” Drive Attachment
• Tape Measure
• Metal Banding Cutter
• Nicopress swage tool for 3/16" wire rope
• Cable Cutter
• Electrical Tape
• Utility Knife
• Laser Level
• Rubber Mallet
WARNING: Use of incorrectly sized tools may cause damage to the machine.

Installation 11
Uncrating Vortek NXT Hoist
The wooden shipping container is a two-piece unit. The top portion that consists of the top, ends and
sides are one unit. There is a bottom skid that the Vortek NXT hoist rides on.
1: The crate top is secured to the bottom skid with wood screws. Remove the screws, four on each
side and two on each end.
2: Lift the crate top off the bottom skid.
3: Cut the banding and remove the poly sheeting from the hoist. Two backbone stiffeners and the
Vortek NXT Hoist Installation Kit will be loosely attached on top of the unit. If you are not able
to use backbone stiffeners, a third set of beam clamps may be provided. Remove these items and
place them in a safe location. They will be required during this installation procedure.
Basic Hoist Components
Note:
If you are mounting the hoist vertically, it will be resting on the top of the hoist. For
information on vertical mounting, see Vertical Mounting on page 20.
M
OT
O
RE
ND
M
OTOR
EN
D
Motor
End
Motor End
Beam Clamps
Backbone
Stiffeners
Backbone
Clamps Tail End
Beam Clamps
Tail
End
Tail End Cable
Drop (Optional)
Motor End Cable
Drop (Optional)
Motor
Control Box
Cables
Out End

12 Vortek NXT Hoist Installation Manual
Attaching Backbone Stiffeners
All Vortek NXT hoist installations require the use of aluminum backbone stiffeners installed on top of
the hoist backbone with two 3/8” threaded rods, four nuts and two steel backbone clamps.
Assemble the backbone stiffener and hardware kit to the hoist as follows:
1: Turn the backbone stiffener on edge with the chamfered corner down and towards the beam
clamps, then slide it under the center lip of the backbone.
2: Repeat this process for the opposing side.
3: Insert the threaded rod through the beam clamp while threading the nut onto the lead end.
4: Continue pushing the rod into the hole on the backbone stiffener and start threading the second
nut onto the lead end; the threaded rod will run into and through the second beam clamp.
Note:
If there is something that obstructs you from using backbone stiffeners, you have the
option to use a third set of beam clamps. For additional information, contact your
ETC representative.
Motor
End
Tail
End
Motor
Drum
Vortek
Load Brake
Gearbox
Sheaves
Motor Brake
Motor Support Frame
Tail Support Frame

Installation 13
5: Tighten both nuts onto the backbone stiffener as shown. Make sure the threaded rod is centered
across the backbone so that it does not stick out of either side of the beam clamps.
6: Place a backbone clamp onto a single side and slide it 15.2 cm (6") past the end of the second
channel.
7: Repeat for the other end of the stiffeners with the second clamp.
Note:
The beam clamps on the motor end of the hoist may be installed in the very first
position. Depending on the installation environment, the installation blocks and
lifting clips may have to be used on the inside of the support I-beams. In this
situation, the backbone stiffeners will have to be installed after the hoist is lifted and
partially clamped in place.
CAUTION:
Do not tighten the set screw on these backbone clamps at this time.

14 Vortek NXT Hoist Installation Manual
Mounting Vortek NXT Hoist
Using Hoist Lifting Clips
Hoist lifting clips are provided only when ordered with the project. Contact ETC Professional Services
for ordering information.
Hoist lifting clips install into the hoist backbone. Shown below is a clip in the backbone channel prior
to being rotated into the proper lifting position, and the clip when it has been locked into the channel.
Tighten the bolts on the lifting clips to 13.5 Nm (10 ft/lb) to secure the clips in place on the backbone.
WARNING: Risk of personal injury and/or damage to the hoist. Do not lift the Vortek NXT
hoist using methods other than the ETC's hoist lifting clips, unless you are
mounting the hoist vertically. For vertical mounting, see
Vertical Mounting
on
page 20 .
WARNING: Verify that the bolts are set and the clip cannot slip out of the backbone
channel.
Prior to lifting, torque the bolts to 13.5 Nm (10 ft/lb) to secure the clips.
1
2
313.5 Nm
10 ft/lb

Installation 15
Hoist Placement
Motor End hoist beam clamps are secured to the hoist backbone and cannot be adjusted. You must
align the Motor End of the hoist with the corresponding edge of the beam flange. This can be
accomplished by using a laser level to distinguish between the leading edge of the I-beam and the
Motor End beam clamp.
Directly attach lift lines or chains to the hoist lifting clip.
WARNING: The hoist weighs approximately 295 kg (650 lbs) out of the crate. Take
precautions when lifting, making sure that the area is roped off and
personnel are away from the lifting area.

16 Vortek NXT Hoist Installation Manual
Lift Hoist to I-beams
1: With the hoist lifting clips securely in place on the hoist backbone, lift the hoist out the skid
approximately 7.6 cm (3").
2: Check that all connections are secure at the hoist lifting clips.
3: When lifting the hoist to the level of the I-beams, stop just short so that the beam clamps can
be adjusted for the spacing of the I-beams.
4: Raise the hoist into position so the backbone is about 12.7 mm (1/2”) below the I-beams and
start tightening the clamps using the 9/16” socket. Only tighten until they contact the top of the
I-beams’s lower flange. Do this for all beam clamps you have supporting the hoist.
5: Apply a light lubricant on the bolt threads and channels before tightening the bolts.
6: The lifting cables can be loosened slightly, allowing the hoist to be adjusted on the I-beam.
7: Confirm the placement of the hoist, and make any final adjustments by sliding the hoist upstage
or downstage on the I-beam as needed. If the backbone stiffeners were not installed earlier,
please do so now.
8: With placement confirmed, tighten the beam clamp bolts to a final torque of 23-27 Nm (17-20
ft/lb) by alternating between the two clamps until the hoist backbone is contacting the I-beam,
CAUTION:
Make sure that the cables do not get caught on anything as the hoist is raised.
Note:
It is helpful to use a cordless drill with a wobble extension drive and socket to tighten
beam clamps. If using a cordless drill, make sure it is set to the minimum torque
setting.
12.7 mm
(1/2 in.)