HyQuest Solutions BAROSSA DDT700 User manual

HyQuest Solutions Pty Ltd
DDT700
© Copyright
Page 1 of 15 ISSUE 6: March 20
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DDT700 BAROSSA DOUBLE DRUM WINCH
INSTRUCTION MANUAL
QUALITY SYSTEM
ISO: 9001
CERTIFIED
HYQUEST SOLUTIONS PTY LTD
48-50 Scrivener St, Warwick Farm, NSW 2170, AUSTRALIA
Phone: [phone] Fax: [phone]
Email: [e-mail]
Web: www.hyquestsolutions.com.au

HyQuest Solutions Pty Ltd
DDT700
© Copyright
Page 2 of 15 ISSUE 6: March 20
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CONTENTS
Contents
CONTENTS...................................................................................................................................................................2
INTRODUCTION .........................................................................................................................................................3
OPERATION.................................................................................................................................................................3
Initial set up & Operational Procedure: ...................................................................................................................3
Dismantling Procedure: ...........................................................................................................................................5
Winch Mode: ...........................................................................................................................................................5
Traversing Mode: ....................................................................................................................................................6
COUNTERS ............................................................................................................................................................7
MAINTENANCE .......................................................................................................................................................... 7
Lubrication ..............................................................................................................................................................7
Weston Brake ..........................................................................................................................................................7
INSPECTION..........................................................................................................................................................8
Electrical System .....................................................................................................................................................8
FAULT FINDING .........................................................................................................................................................9
SPECIFICATIONS...................................................................................................................................................... 10
FITTING C1 CONNECTOR TO AMERGRAPH CABLE......................................................................................... 11
FITTING ANGLE PLUG TO AMERGRAPH CABLE.............................................................................................. 12
Angle Plug Assembly AP02.......................................................................................................................................13
FITTING TEE PLUG TO AMERGRAPH CABLE.................................................................................................... 14
Angle Plug Assembly TP02 .......................................................................................................................................14
APPENDIX A ............................................................................................................................................................ 15
INSTALLATION....................................................................................................................................................... 15

HyQuest Solutions Pty Ltd
DDT700
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Page 3 of 15 ISSUE 6: March 20
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INTRODUCTION
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The HyQuest Solutions Barossa double drum winch is based on the long established approach to
obtaining current meter observations and sediment samples in streams of moderate widths. The
principal advantage of the double drum concept lies with the ease of traversing, as the forces exerted
by the gauging weight are largely cancelled out. The winch exhibits state-of-the-art design features,
representing years of both in-house and field development. It comprises a rugged cast aluminium body
and cable drums, with stainless steel shaft components and corrosion resistant fasteners throughout.
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OPERATION
The current meter can be fitted with a stabiliser tail fin which is attached to a hanger bar and Columbus
gauging weight in sizes of 7, 14, 23, 34, 45 and 68Kg. This assembly is suspended from the gauging
winch by the amergraph signal cable.
HyQuest Solutions provides a range of counters to operate with the winch. The models available are
CMC20A, CMCsp, PVD100, PVD200 and HydroTab/CMCbt.
Initialsetup&OperationalProcedure:
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A typical installation is depicted in the appendix of this manual. The layout shown in the appendix
is based on HyQuest Solutions standard steelwork components, all of which can be supplied ready
for installation.
Alternatively, drawings can be provided for the components to be fabricated elsewhere.
However, as a minimum, the sheave block assembly should be supplied.

HyQuest Solutions Pty Ltd
DDT700
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Page 4 of 15 ISSUE 6: March 20
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For light gauging
weights use this
position on the handle
1. Install winch and traveller block as shown in the appendix
2. Fit handle, screw knob onto the shaft.
3. For the first time fit the winch to the required location as shown in the appendix. Install
winch and traveller block as shown in the appendix
4. Disconnect Cl cable connector from tension spring on winch, wind out amergraph cable over
layer winding sheave of winch and then overꞏthe sounding sheave of the traveller block (it is
necessary to remove lower section of traveller block for this operation). Connect to the
current meter hanger bar. Fit the angle plug to current meter.
5. Remove the end of the upper traversing cable from its anchorage and connect to the stream
side of the traversing block.
6. Similarly, release the lower traversing cable and pass end over the layer winding
sheave of the traversing drum, and fit to the slotted hole in the slipring end of the
drum refer to appendix.
7. Remove soft clamp from traversing cable and main cable.
8. With traversing drum disengaged, wind the weight up to the traveller block - engage
traversing drum and lower the weight to the ground. Repeat this procedure until the
traversing cables are tensioned.
9. Connect the current meter revolution counter to the winch terminals and check circuit operation.
10. Position weight over zero chainage indicator and zero traversing counter.
11. Proceed with discharge measurement.
For heavy gauging weights,
use this position on the handle
to gain more torque
Please Note the drive handle side could be either left or right
and can be specified by the customer at time of order

HyQuest Solutions Pty Ltd
DDT700
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DismantlingProcedure:
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1. Traverse traveller block to operating side position.
2. Tie traveller block in position near winch.
3. Attach soft clamp to traversing cables and main cable on river side of traveller block.
4. Disengage traversing drum, then lower sounding weight to the ground (thus reducing tension
in the cables).
5. Remove traversing cable from drum and connect to anchorage chain with padlock. Refer to
appendix
6. Loosen soft clamp, remove traversing cable end from traveller block, pull cable in and attach
to padlock.
7. Tighten soft clamp.
8. Remove traveller block from main cable.
9. Disconnect current meter, weight and current meter counter.
10. Wind on Amergraph cable and secure Cl Connector to tension spring.
11. Remove winch from mountings.
WinchMode:
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Barossa Winch shown in "winch mode", that is the traverse drum is out of mesh with the sounding
drum and is prevented from rotating by the drum stop. In this mode, the sounding weight can be
raised and lowered whilst the traversing block remains stationary
It will be observed that if the winch handle is released, the weight will be held in position - this is due
to the automatic (Weston) brake. To lower, it is necessary to wind the weight down. This again is due
to the influence of the Weston brake. For the brake to operate in this manner, the pawl must engage
with the ratchet wheel on the operating shaft. With the pawl engaged, a loud click will be heard as the
handle is rotated in a clockwise direction.

HyQuest Solutions Pty Ltd
DDT700
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Page 6 of 15 ISSUE 6: March 20
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TraversingMode:
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Barossa Winch shown in “traversing mode” that is the drum ring gears are in mesh and the drums
rotate in opposite directions when the operating handle is moved. In this mode, the traveller block
can be traversed in and out.
The traversing drum cradle pivots under the influence of the disengaging handle mounted on the
opposite side. To engage the drum gears, release the locking handle and whilst holding the disengaging
handle with the left hand, rotate operating handle slightly until gear teeth can be meshed, then move
disengaging handle down with the left hand and lock it in place.
A typical installation is depicted in the appendix. The layout shown in the appendix is based on
HyQuest Solutions standard steelwork components, all of which can be supplied ready for
installation. Alternatively, drawings can be provided for the components to be fabricated elsewhere.
However, as a minimum, the sheave block assembly should be purchased, please note customer has
to order the sheave block separately as it is not part of the winch order.

HyQuest Solutions Pty Ltd
DDT700
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Page 7 of 15 ISSUE 6: March 20
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COUNTERS
The winch is fitted with two counters. The TRAVERSING counter is situated to the right of the
traverse drum and registers in in EITHER centimetre (10mm) OR decimetre (100mm) resolution.
Imperial model available in resolutions of either 1ft or 0.1ft. The SOUNDING counter is situated on
the control panel and registers in centimetre resolution (10mm) for metric and 1/10” of a foot (0.1foot)
for imperial.
MAINTENANCE
For the most part, the Barossa winch is maintenance free. However, periodic maintenance is
required as set out below.
Lubrication
1. Grease the Weston brake every six months through the grease nipple located on the outside
of the main shaft. Ampol APlW or similar water-resistant grease is recommended. Following
this, engage pawl and wind operating handle half a turn in both directions approximately five
(5) times to ensure that grease is spread on the brake screw.
2. Wipe the layer winding screws every six (6) months with a clean rag and solvent,
preferably Trichloroethylene. Inspect for damaged threads and repair as necessary. No
lubrication is normally required but a light spray of WD40.
3. The drum gear teeth should be lightly lubricated every six (6) months with grease.
4. The sounding drum slipring should be wiped every three (3) months with a clean, dry rag and
solvent such as Trichloroethylene, then lightly sprayed with a non‐insulating lubricant such as
WD40.
WestonBrake
The Weston brake is a proven and reliable component of the winch drive and will provide
many hours of service life. However, in the event of a breakdown, the following procedure
should be followed.
1. Remove all sources of external loading from the drums.
2. Engage pawl and wind operating handle quarter turn anticlockwise. This will loosen
the brake screw.
3. Remove grease nipple, washer and operating handle from brake shaft.
4. Remove transmission cover (six setscrews), leaving brake shaft and bearing in
position on the winch.
5. Remove nyloc nut.
6. Remove counter and mounting bracket.

HyQuest Solutions Pty Ltd
DDT700
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Page 8 of 15 ISSUE 6: March 20
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7. Remove chain guard, spacer, sprocket and drive chain from end of brake shaft.
8. Remove drag brake.
9. Slide brake shaft out of winch.
10. Unscrew brake drum from Weston brake screw and remove both.
11. Assembly of these components back in to the winch is a reversal of Steps 1 ‐9.
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INSPECTION
1. Remove nylon pinion (four setscrews) and separate the ratchet wheel and the two (2)
brake pads.
2. With the brake disassembled, clean all metal components thoroughly in a solvent, such as
Trichloroethylene.
Note: Brake pads should only be wiped with a clean, dry rag.
3. Inspect the surfaces of the ratchet wheel and brake pads for scores. Repair if necessary by
placing each of the components onto a sheet of fine grade emery cloth and work in a circular
motion.
Note: The Weston brake will not operate smoothly if either the ratchet wheel or pads are
NOT perfectly flat.
4. Check that brake pad thickness is not less than 1.5mm Replace if necessary.
5. Check the brake screw surfaces for wear or corrosion and repair with a fine file or emery
paper if necessary.
Note: Lack of use of the Weston brake could cause seizure of the brake screw. To avoid
this, follow lubrication recommendation (Step 1)
6. Coat the brake screw and bore of ratchet wheel with grease before assembly.
7. Smooth any wear marks on the nylon gear and pinion teeth with a medium grade file.
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ElectricalSystem
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The winch is designed for operation with conventional current meters using single core insulated
meter suspension cable.
A "quick connect" terminal is located at the left-hand end of the sounding drum, providing an electrical
connection between the slipring and suspension cable conductor, thus allowing the cable to be fitted
without removing the drum.

HyQuest Solutions Pty Ltd
DDT700
© Copyright
Page 9 of 15 ISSUE 6: March 20
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FAULTFINDING
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The following is included to assist field staff to remedy electrical problems that can occur when
taking current meter observations.
Using the counter to indicate a complete circuit, proceed as follows.
1. Bridge out red and black terminals situated on control panel. If the counter does not operate,
repair or replace counter.
2. Connect the red terminal to frame. No indication shows that black terminal is not properly
connected to frame. Check for corrosion under terminal, or loose mounting.
3. Bridge slipring to frame. Operation suggests the connection through brush to the red terminal
is sound ‐proceed to step 4.
4. Failure to operate suggests either a break in red lead from brush to red terminal or
broken/sticking brush. To inspect brush, remove and ensure that it moves freely in holder.
If bush is broken, reclaim unbroken portion and extend the spring, thus providing a
temporary connection until a replacement can be fitted.
5. Bridge out current meter terminals. Operation indicates a failure in the meter contacts ‐
repair. No operation indicates a failure in the circuit between the slipring and the meter i.e.
the circuit fault is in the suspension cable. Check quick connect terminal at winch. Check
cable adjacent to meter. Check for damaged or bent cable. Repair or replace sounding cable.

HyQuest Solutions Pty Ltd
DDT700
© Copyright
Page 10 of 15 ISSUE 6: March 20
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SPECIFICATIONS
Load Capacity: Designed for weights up to 70 Kg (154 lb)
Frame: Robust Aluminium, Powder Coated.
Sounding Drum: Cast Aluminium 600mm Circumference, fitted with silver plated slipring,
and depth counter.
Counter (Sounding): Six digit resettable, registering depth in centimetre (1cm resolution) for
metric or 1/10 of a foot (0.1foot) for imperial.
Traversing Drum: Cast Aluminium 600mm Circumference, fitted with traverse counter.
(Detachable when not required).
Counter (Traversing): Six digit resettable, registering distance in EITHER centimetre (10mm) OR
decimetre (100mm) resolution. Imperial model available in resolutions of
either 1ft or 0.1ft.
Drum
Capacity:
Operation:
Dimensions:
Packing
Details:
43m of 4.0mm, 57m of 3.2mm (1/8”) and 70m of 2.5mm (1/10”)
Manual
Double Drum - Length 600mm (24”), Width 560mm (22”), Height 470mm
(18.5”), Weight 36Kg (79.4 lb).
Double Drum – 64 Kg (141 lb), 0.3m3