Electro-Voice XARRAY FLY User Manual
X-ARRAY™ CONCERT SYSTEMS
Flying Manual
and Structural Ratings
X-Array™ Loudspeaker Systems
RIGGING-SAFETY WARNING
This document details general rigging practices appropriate to the sound industry, as they would apply
to the rigging of Electro-Voice X-Array™ loudspeaker systems. It is intended to familiarize the reader
with standard rigging hardware and techniques for suspending X-Array™ loudspeaker systems overhead. Only persons with the knowledge of proper hardware and safe rigging techniques should attempt
to suspend any sound systems overhead. Prior to suspending any Electro-Voice X-Array™ loudspeaker
systems overhead, it is essential that the user be familiar with the strength ratings, rigging techniques
and special safety considerations outlined in this manual. The rigging techniques and practices recommended in this manual are, of necessity, in general terms to accommodate the many variations in loudspeaker arrays and rigging configurations. As such, the user is expressly responsible for the safety of all
specific X-Array™ loudspeaker-array designs and rigging configurations as implemented in practice.
All of the general rigging material contained in this manual is based on the best available engineering
information concerning materials and practices, as commonly recognized in the United States, and is
believed to be accurate at the time of the original printing. As such, the information may not be directly
applicable in other countries. Furthermore, the regulations and requirements governing rigging hardware
and practices may be superseded by local regulations. It is the responsibility of the user to ensure that
any Electro-Voice loudspeaker system is suspended overhead in accordance with all current federal,
state and local regulations.
All specific material concerning the strength ratings, rigging techniques and safety considerations for the
X-Array™ loudspeaker systems is based on the best available engineering information concerning the
use and limitations of the products. Electro-Voice continually engages in testing, research and development of its loudspeaker products. As a result, the specifications are subject to change without notice. It
is the responsibility of the user to ensure that any Electro-Voice loudspeaker system is suspended overhead in accordance with the strength ratings, rigging techniques and safety considerations given in this
document and any manual update notices. All non-Electro-Voice associated hardware items necessary
to rig a complete X-Array™ loudspeaker array (grids, chain hoists, building or tower supports and miscellaneous mechanical components) are the responsibility of others.
Electro-Voice
February, 1998
X-Array™ Loudspeaker Systems
TABLE OF CONTENTS
RIGGING-SAFETY WARNING
0. INTRODUCTION
1. X-ARRAY™ RIGGING SYSTEM
1.1 Overview of the X-Array™ Flying Systems............................................................................ 1-2
1.2 Loudspeaker Enclosure Details ............................................................................................. 2-5
1.3 Rigging Hinge Details ...................................................................................................... ...... 5 -7
1.4 Rigging Strap Details ............................................................................................................. 7-8
1.5 Grid Details ............................................................................................................................... 8
2. X-ARRAY™ FLYING TECHNIQUES
2.1 Enclosure and Horn Orientation .......................................................................................... 9-10
2.2 Adjusting the Vertical Angles ............................................................................................. 10-12
Using the Xrsl (long wire-rope rigging strap) Between Enclosures ........................................ 10
PAGES
Using the Xrsl (at the Grid ................................................................................................. 10-11
Using the Xrss (short wire-rope rigging strap) Between Enclosures ................................. 11-12
Using the Xrss at the Grid ......................................................................................................11
Multiple Enclosure Angles ...................................................................................................... 12
2.3 Adjusting the Horizontal Angles ......................................................................................... 12-13
2.4 Balancing and Distributing the Load .................................................................................. 13-14
Array Load Distribution...................................................................................................... 13-14
Balancing the Grid.................................................................................................................. 14
2.5 Using Pull-Up Lines ........................................................................................................... 14-15
Pull-Up Line Techniques ................................................................................................... 14-15
CAUTIONS for Pull-Up Lines ................................................................................................. 15
3. RIGGING-STRENGTH RATINGS, SAFETY .............................................................................. 15-23
FACTORS AND SPECIAL CONSIDERATIONS
3.1 Working-Load Limit and Safety Factors ...................................................................... 15-16
Definitions.................................................................................................................... 15-16
CAUTIONS for Working-Load Limits and Safety Factors................................................. 16
3.2 Structural Rating Overview.......................................................................................... 16-17
3.3 Simplified Structural-Rating Guidelines ............................................................................ 17
The Guidelines ................................................................................................................. 17
CAUTIONS for the Simplified Structural-Rating Guidelines ........................................ 17-19
Discussion of Array Examples.......................................................................................... 19
X-Array™ Loudspeaker Systems
3.4 Complex Structural-Rating Analysis .................................................................................. 19-20
Rear Rigging Point Structural-Strength Rating.................................................................. 19-20
(Xrhg, Xrhp, Xrhl & NH32102-2)
Xrhg (grid hinge)
Xrhp (pick-up hinge)
Xrhl (linking hinge)
NH32102-2 (New Haven double-stud swivel-ring fitings)
Front Rigging Point Structural-Strength Rating ................................................................. 20-21
(Xrss, Xrsl & NH32102-2)
Xrss (short wire-rope rigging strap)
Overall Enclosure Structural-Strength Rating ........................................................................ 21
CAUTIONS for a Complex Structural-Rating Analysis ........................................................... 21
3.5 Special Considerations ...................................................................................................... 21-23
Double-Stud Fittings.......................................................................................................... 21-23
Flying a Single Enclosure.......................................................................................................23
3.6 Electro-Voice Structural Analysis Procedures ........................................................................ 23
4. RIGGING INSPECTION AND PRECAUTIONS.......................................................................... 23-24
5. REFERENCES................................................................................................................................ 24
Rigging References
Mechanical Engineering References
Acoustical Engineering References
APPENDICES .................................................................................................................................. 24
A. SERVICING THE X-ARRAY™ RIGGING................................................................................. 25
B. X-ARRAY™ RIGGING ACCESSORIES................................................................................... 25
X-Array™ Loudspeaker Systems
0. INTRODUCTION
The X-Array™ product line represents important
advancements in concert-sound-reinforcement
technology. The design goals called for the highest acoustic-output capability with the highest
fidelity, in lightweight, compact enclosures that
were easy to array. The development began with
a clean sheet of paper and took an integrated approach. The individual loudspeaker drivers, horns,
enclosures, rigging hardware and system configurations were designed from the ground up specifically for this high-performance application. A brief
description of the X-Array™ product line is included below. Consult the individual system engineering data sheets for detailed specifications.
Xf: Far-field, two-way, MB/HF loudspeaker system with a 40°H x 20°V coverage pattern. The
system has two ND12A 305-mm (12-in.) MB
drivers and two ND5-16 76-mm (3-in.) HF compression drivers. The Xf utilizes the full-size
X-Array™ enclosure shell and the standard
X-Array™ flying hardware.
Xn: Near-field, three-way, LF/MB/HF loudspeaker system with a rotatable 60° x 40° coverage pattern. The system has one EVX-180B
457-mm (18-in.) woofer, one ND12A 305-mm
(12-in.) MB driver and one ND5-16 76-mm (3-in.)
HF compression driver. The Xn utilizes the fullsize X-Array™ enclosure shell and the standard
X-Array™ flying hardware.
Xb: Bass loudspeaker system with two
EVX-180B 457-mm (18-in.) woofers. The Xb
utilizes the full-size X-Array™ enclosure shell
and the standard X-Array™ flying hardware.
Xds: Subwoofer loudspeaker system with two
EVX-180B 457-mm (18-in.) woofers. The Xds
utilizes the double-wide X-Array™ enclosure
shell and does not have flying hardware.
Xcn: Compact near-field, two-way, MB/HF loudspeaker system with a rotatable 60° x 40° coverage pattern. The system has one ND12A 305-mm
(12-in.) MB driver and one ND5-16 76-mm (3-in.)
HF compression driver. The Xcn utilizes the halfsize X-Array™ enclosure shell and the standard
X-Array™ flying hardware.
Xcb: Compact bass loudspeaker system with
one 457-mm (18-in.) EVX-180B woofer. The Xcb
utilizes the half-size X-Array™ enclosure shell
and the standard X-Array™ flying hardware.
Numerous accessories are available to complete
an X-Array™ loudspeaker system, including rigging hardware, digital electronic controllers,
power amplifiers, cables, racks, cases, dolly
boards and speaker covers. See
B. X-Array™ Rigging Accessories
Appendix
for a list of
available accessories and where to purchase
them. See
Rigging
Appendix A. Servicing the X-Array™
for service information.
1. X-ARRAY™ RIGGING SYSTEM
1.1 Overview of the X-Array™ Flying System
The X-Array™ rear-hinge/front-strap flying system
makes constructing arrays easy, predictable and
repeatable. The hinging concept, combined with
the trapezoidal enclosures, allows arrays to be
constructed with the least possible spacing between enclosures.
A basic two-enclosure flying system is shown in
Figure 1 that illustrates the integral components
that make up a typical X-Array™ flying system.
All of the flying X-Array™ loudspeaker systems
utilize horizontal rigging-track hardware on the
back of the enclosure (at both the top and bottom)
and vertical rigging-track hardware on the front
of the enclosures (at both the left and right sides).
The rear rigging-hinge hardware provides the
page 1
X-Array™ Loudspeaker Systems
primary support for the loudspeaker enclosures,
while the front rigging hardware is mainly for aiming the enclosures vertically. (The front does provide some secondary support, however.)
Figure 1a illustrates an array column suspended
with a grid. Like the loudspeaker systems, the grid
utilizes horizontal rigging-track hardware at the
back and vertical rigging-track hardware at the
front. The top enclosure is secured to the grid
with two quick-release Xrhg grid hinges at the
rear, and two quick-release Xrss short wire-rope
rigging straps at the front. The grid hinge has only
one possible vertical attachment position on both
the enclosure and the grid. The front straps, however, have six possible vertical attachment positions to choose from on the enclosure and two
possible vertical attachment positions to choose
from on the grid. The grid hinges allow the enclosure to pivot from its top back corner. The vertical
angle of the top enclosure, relative to the grid, is
set by the linear position of the front rigging straps
in the track on the front of the enclosure and on
the grid.
The bottom enclosure shown in Figure 1a is linked
to the top enclosure with two quick-release Xrhl
linking hinges at the rear and two quick-release
Xrsl long wire-rope rigging straps at the front. The
linking hinges allow the bottom enclosure to pivot
from the back corner of the top enclosure. The
vertical angle of the bottom enclosure, relative to
the top enclosure, is set by the linear position of
the front rigging straps in the track on the front of
the top and bottom enclosures. Additional enclosures may be linked together in the same fashion,
as long as the working-load limits for any of the
enclosures, rigging hinges or straps are not exceeded. The array column is raised into position
by a motorized chain hoist of sufficient load rating.
Figure 1a shows the short Xrss rigging straps
securing the top enclosure to the grid and the
long Xrsl rigging straps linking the two enclosures
because this is the most common configuration;
however, the straps may be interchanged in
many circumstances. When the short Xrss rigging
straps are used between the top enclosure and
the grid, the enclosure may be angled upward
relative to the grid or downward a moderate
amount. When the long Xrsl rigging straps are
used between the top enclosure and the grid, the
enclosure may be hung parallel to the grid, or
angled downward substantially relative to the grid.
When the long Xrsl straps are used between enclosures, the bottom enclosure may be hung
parallel to the top enclosure or angled downward
substantially relative to the top enclosure. When
the short Xrss straps are used between enclosures, the bottom enclosure may be hung parallel
to the top enclosure or angled downward a moderate amount relative to the top enclosure.
When a grid is used, each array column must
be balanced by adjusting the position of the grid
hanger towards the front or back until the grid
hangs level. Several of the grids may be connected together horizontally and raised in unison.
When using the grid, the splay angle between
array columns is adjusted by the positioning of the
grid retractable-coupler arms.
In permanent installations, the motorized chain
hoists and grids are sometimes eliminated, and
the loudspeaker columns can be secured directly
to the building structure. This application is shown
in Figure 1b. The back of the top enclosure is sus-
pended with two Xrhp pickup hinges. Each Xrhp
pickup hinge utilizes standard chain that will accept chain connectors, shackles or other standard
rigging hardware which are, in turn, secured to
the building structure via custom wire-rope or
chain assemblies. The front of the enclosure is
suspended by two New Haven NH32102-2
double-stud swivel-ring fittings attached to the
front track of the enclosure and which are, in turn,
secured to the building structure via two custom
wire-rope or chain rigging assemblies. The hardware and techniques used to secure and angle
the bottom enclosure to the top enclosure are
identical to the previously described case where
a grid was employed.
In installations where a custom grid is employed
that does not use track that is compatible with the
X-Array™ Xrhg grid hinge or the Xrss or Xrsl rigging straps, the Xrhp pickup hinge and custom
wire-rope rigging straps that utilize New Haven
NH32102-2 double-stud swivel-ring fittings can
be used to suspend the top enclosure as illustrated in Figure 1b.
Note that the weight of an array can be quite substantial and the grid, chain hoists and building
structural supports used to suspend the array
must be capable of supporting such a load with
a sufficient safety factor. The reader is directed to
section
5. References
of this manual for a list of
rigging references (for background in general rigging practice) and mechanical engineering references (for background in structural engineering
analysis).
1.2 Enclosure Rigging Hardware Details
All of the flying X-Array™ models utilize identical
rigging hardware, and they all have the same
strength ratings. Figure 2 shows key dimensions,
weights and the centers of gravity for all of the
X-Array™ systems.
A proprietary high-strength aluminum-alloy track
is used at the back of the enclosures near the top
page 2
353.8 mm
(13.93 in.)
353.8 mm
(13.93 in.)
X-Array™ Loudspeaker Systems
C
L
584.2 mm
(23.00 in.)
353.8 mm
(13.93 in.)
C
L
584.2 mm
(23.00 in.)
O
9.0
TYP
733.2 mm
(28.87 in.)
914.4 mm
(36.00 in.)
O
9.0
TYP
733.2 mm
(28.87 in.)
758.8 mm
(29.88 in.)
WEIGHT: 87.1 kg (192 lb)
758.8 mm
(29.88 in.)
WEIGHT: WITHOUT EXTERNAL RIGGING: 87.1 kg (192 lb)
WITH EXTERNAL RIGGING: 90.2 kg (199 lb)
384.1 mm
(15.12 in.)
FIGURE 2a - Xf SYSTEM
WEIGHT: 83.5 kg (184 lb)
WEIGHT: WITHOUT EXTERNAL RIGGING: 83.5 kg (184 lb)
WITH EXTERNAL RIGGING: 86.6 kg (191 lb)
438.5 mm
(17.26 in.)
457.2 mm
(18.00 in.)
C
L
584.2 mm
(23.00 in.)
9.0
TYP
733.2 mm
(28.87 in.)
914.4 mm
(36.00 in.)
736.6 mm
(28.98 in.)
C
L
1166 mm
(45.92 in.)
O
WEIGHT: 87.1 kg (192 lb)
WEIGHT: WITHOUT EXTERNAL RIGGING: 87.1 kg (192 lb)
758.8 mm
(29.88 in.)
409.2 mm
(16.11 in.)
FIGURE 2b - Xn SYSTEM
18°
TYP.
667.2 mm
(26.27 in.)
758.8 mm
(29.88 in.)
WEIGHT: 121 kg (267 lb)
WITH EXTERNAL RIGGING: 90.2 kg (199 lb)
441.3 mm
(17.38 in.)
423.3 mm
(16.67 in.)
page 3
914.4 mm
(36.00 in.)
FIGURE 2c - Xb SYSTEM
457.2 mm
(18.00 in.)
FIGURE 2 - X-ARRAY LOUDSPEAKER SYSTEMS
914.4 mm
(36.00 in.)
FIGURE 2d - Xds SYSTEM
457.2 mm
(18.00 in.)
X-Array™ Loudspeaker Systems
(17.07 in.)
433.6 mm
WEIGHT: 55.8 kg (123 lb)
(29.88 in.)
758.8 mm
(28.87 in.)
733.2 mm
9.0°
TYP
L
C
353.8 mm
353.8 mm
(13.93 in.)
(13.93 in.)
9.0°
TYP
733.2 mm
(28.87 in.)
758.8 mm
(29.88 in.)
C
L
584.2 mm
(23.00 in.)
(15.40 in.)
391.2 mm
WEIGHT: 60.8 kg (134 lb)
584.2 mm
(23.00 in.)
595.9 mm
595.9 mm
(23.46 in.)
(23.46 in.)
301.6 mm
292.1 mm
(11.88 in.)
(11.50 in.)
FIGURE 2f - Xcb SYSTEM
FIGURE 2 (cont’d) - X-ARRAY LOUDSPEAKER SYSTEMS
FIGURE 2e - Xcn SYSTEM
and bottom for the attachment of two Xrhg, Xrhl
or Xrhp rigging hinges. The track/bracket assembly is extruded as a single piece. One assembly
ties into the back and top of the enclosure, while
a second assembly ties into the back and bottom
of the enclosure. High-strength, aluminum-alloy
bars inside the enclosure tie the top and bottom
track/bracket assemblies together, minimizing
the load applied to the enclosure shell. The track
dimensions are similar to the widely used heavyduty aircraft L-track (such as the New Haven
NH34030-3HD or ATM Fly-Ware™ ATM-TRACK).
The cutouts in the rear rigging track are shown in
Figure 3a. The large cutout in the center of the
track is for inserting the rigging hinges. The small
holes in the base of the track are for locking the
rigging hinges. The round cutouts on either side
are provided so that two New Haven NH32102-2
double-stud swivel-ring fittings may be installed
for light-duty lifting applications and for pull-ups.
Key dimensions for the rear rigging hardware are
presented in Figure 3a. (See section
3. RiggingStrength Ratings, Safety Factors and Special
Considerations
for a detailed discussion of the
structural strength of the enclosure rear rigging
points.)
At the front of the enclosure is another pair of
proprietary high-strength, aluminum-alloy track/
bracket assemblies which are also extruded as a
single piece. One assembly ties into the left side,
top, bottom of the enclosure, while a second assembly ties into the right side, top and bottom of
the enclosure. The front track extends from the
top to the bottom on both sides of the enclosure,
eliminating the load applied to the enclosure shell.
These track dimensions are also similar to the
widely used heavy-duty aircraft L-track (New
Haven NH34030-3HD or ATM Fly-Ware™ ATMTRACK). On both sides of the enclosure, the front
rigging track has six cutouts near the top and
bottom, as shown in Figure 3b. The New Haven
NH32102-2 double-stud swivel-ring fittings on
the Xrss and Xrsl wire-rope rigging straps may be
installed at any of the cutouts. The relative angle
between a pair of enclosures (or the top enclosure and the grid) is set by the position of the
front rigging-strap fittings in the track cutouts.
Key dimensions for the front rigging hardware
are presented in Figure 3b. (See section
3. Rigging-Strength Ratings, Safety Factors and Special
Considerations
for a detailed discussion of the
structural strength of the enclosure front rigging
points.)
To facilitate the installation and removal of the
linking hinges, alignment feet are installed on the
top and bottom of the X-Array™ enclosures. Male
feet (protruding feet) are located on the bottom
of the enclosures, while female feet (concave
page 4
X-Array™ Loudspeaker Systems
HOLE FOR RIGGING
HINGE LOCKING PIN
CUTOUT FOR INSERTING
RIGGING HINGES AND
DOUBLE-STUD FITTINGS
FIGURE 3a - ENCLOSURE REAR RIGGING TRACK
FIGURE 3b - ENCLOSURE FRONT RIGGING TRACK
CUTOUT FOR LOCKING
DOUBLE-STUD FITTING
79.0 mm
(3.11 in.)
25.4 mm
(1.00 in.)
48.0 mm
(1.89 in.)
TYP.
TYP.
the chain near the ends of the track, as shown in
Figure 5a. (Note: If one grid hinge is installed incorrectly with the chain at the center of the track,
the second grid hinge will not fit into the track cutout.) Key dimensions for the Xrhg grid hinges and
the enclosure are presented in Figures 4a and 5a.
To install an Xrhg grid hinge into the track of an
enclosure, grasp one of the hinge bases and
FIGURE 3 - ENCLOSURE RIGGING HARDWARE DETAIL
dishes) are located on the top. When one enclosure is stacked or lowered on top of another, the
male feet on the bottom of the upper enclosure
slide into the female feet on the top of the lower
enclosure, automatically aligning the enclosures.
If the enclosures do not self align, a light sideways push is all that is needed to make the feet
engage and align. These features allow fast
assembly and disassembly of large loudspeaker
arrays in touring applications.
1.3 Rigging Hinge Details
Xrhg Grid Hinge: Two Xrhg grid hinges are used
to attach the back of an X-Array™ enclosure to
the back of an X-Array™-compatible grid. (See
section
1.5 Grid Details
for a discussion of the
grid.) Each grid hinge consists of two precisionmachined steel bases connected by an alloy-steel
chain, as shown in Figure 4a. Each grid-hinge
base has a locking pin which locks the hinge in
place horizontally in the track on the grid or
X-Array™ enclosure. (See section
3. RiggingStrength Ratings, Safety Factors and Special
Considerations
for a detailed discussion of the
structural strength of the grid hinges.)
The Xrhg grid rigging hinges need not be installed
in the top enclosure and the grid simultaneously.
The length of chain allows the grid hinges to be
installed in the grid first. The grid can then be
floated above the top enclosure while the other
ends of the grid hinges are installed in the track
at the rear of the enclosures. The grid hinges
must be used in pairs and must be installed with
firmly insert the hinge base into the long center
cutout in the track, pressing in until the springloaded locking pin is fully retracted. Then apply
pressure to slide the hinge base sideways towards the end of the track until the spring-loaded
locking pin drops into the hinge-locking-pin hole in
the base of the track. Once the locking pin is fully
engaged, the grid hinge base will be immovable
in the track. ALWAYS CHECK TO MAKE SURE
THE GRID-HINGE BASES ARE SECURELY
LOCKED INTO THE TRACK, AND THAT THE
LOCKING PINS ARE FULLY ENGAGED IN THE
TRACK BEFORE LIFTING ANY LOUDSPEAKER
ENCLOSURES OVERHEAD. Use the same technique for installing the other end of the Xrhg grid
hinge in the track at the rear of the grid.
To remove the Xrhg grid hinge, grasp the lockingpin knob and pull out while applying pressure on
the hinge to slide the hinge base toward the long
cutout at the center of the track. The hinge base
page 5
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