Rev.

03/09/2018

User Manual
Midgard winch system
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Contents:
1. Introduction .................................................................................................................................... 3
1.1 Contacts in Aqualine AS 3
1.2 Warnings, precautions and please note 4
1.3 Repairs and replacements 4
1.4 Recycling and the environment 4
1.5 General description 5
2. Specifications................................................................................................................................ 6
3. Installation and cables .................................................................................................................. 7
3.1 Remote control 11
4. Preventive measures and use .................................................................................................... 13
4.1 Rope replacement 13
5. Using the Aqualine Midgard winch system .............................................................................. 14
5.1 Preparations for use 14
5.2 Lowering the sinker tube using winches 14
5.3 Lifting the sinker tube using winches 15
5.4 Disconnection after use 15
6. Revision history – User manual ................................................................................................. 17

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1. Introduction
The Midgard winch system comprises:

• Winches, incl. motors

• One (1) control cabinet, incl. frequency converters

Please read this manual before using/installing the winch system. The winch is a very
powerful piece of machinery. In the event of negligent use or user error, there is a certain risk
of damage to equipment or personal injury. The system includes several features to minimize
this risk, but caution during use is absolutely essential to the operator’s safety. Correct
installation of the winch is a requirement for correct use.

1.1 Contacts in Aqualine AS

Tel.
Directory: 73 80 99 30.
Outside business hours: 958 86 738

Installation Supervisor, winches: Joakim Løveng - joakim@aqualine.no

See our website for more information about which person to contact:
www.aqualine.no/kontakt/ansatte

Website: www.aqualine.no
E-mail: aqualine@aqualine.no

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1.2 Warnings, precautions and please note

These are presented in this manual in the following form:

WARNING: Procedures that must be followed to the letter to eliminate the risk of personal
injury.
PRECAUTION: Calls attention to procedures that must be followed in order to prevent
damage to components-
PLEASE NOTE: Focuses on methods that will make a job easier or offers useful information.

USING THE WINCH

Winches must not be used for purposes other than those described in this user
manual, lifting/lowering sinker tube.

Aqualine accepts no liability for any claims based on use beyond what is
described in this user manual.

The winch system is designed for efficient lifting and lowering of the sinker tube.

1.3 Repairs and replacements

PRECAUTION:

Repairs to and/or replacement of components beyond the winch rope must only be
performed by personnel authorized by Aqualine.

Before contacting Aqualine, please have the following information ready: Serial no. of floating
collar and/or serial no. of winch.

1.4 Recycling and the environment

Dumping used gear oil (BP Energear Hypo 85W-140 or SAE 85W-140) in the sea, ground,
sewage or drainage systems or waterways is illegal. Take used oil to an authorized waste
management company. When in doubt, contact local authorities for information about how to
dispose of this type of waste.

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1.5 General description

The winch is electric, operated by an electric motor driving a worm gear via a reduction
gearbox. The motor/reduction gearbox operates the drum via a worm and a worm wheel.

The irreversible worm and worm wheel prevents the load from driving the winch backwards.
The winch is reversible, with a “power-in” and “power-out” switch on the control panel.

Figure 1: Aqualine Midgard winches.

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2. Specifications

Reduction gear: Heavy duty worm and worm wheel gearbox for long and problem-free life.

Drum: Drum made from marine grade 316 stainless steel.

Brake: The irreversible handling of the worm and worm wheel ensures strong brake effect.

MIDGARD WINCH SYSTEM

Nominal pulling power, first layer 2,200kg
Speed, first layer (no load) 0.9m/min
Rope diameter 11mm to 15mm
Rope length, max. 30m
Dimension, drum 117mm dia. x 290mm long
Weight, winch only 52.5kg
Weight, complete 85kg
Weight, main housing 65kg
Weight, main housing incl. rack 100kg

MIDGARD WINCH SYSTEM

Ampere, max. 4.5 Amp
Ampere, normal operation 3.8 Amp
Pulling power, first layer 21.57 kN (2,200 kg)
Pulling power, top layer 11.76 kN (1,200 kg)

ELECTRIC MOTOR AND REDUCTION GEARBOX

Electric motor 230 Volt. 50Hz. 3-phase.
Motor type Flange-mounted. 160mm dia. Flange
Motor speed 1430 rpm
Motor output 1.5 kW
Reduction gearbox 2-step. 12.08:1 reduction
Output torque 123 Nm
Output speed 116 rpm
Recommended generator size 15 kW
Circuit breakers power supply 32 Amp
Type of plug 3-phase
Volt alternatives, power supply 230V/400V

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3. Installation and cables

The cross bracket installed above the drum must be securely fastened when the winch is
installed.

Figure 2: Standard winch configuration in a 10-winch system.

The main housing has circuit breakers, frequency converters and an antenna for remote
control of the winches.

WARNING:

Repairs and modifications inside the control cabinet must be performed by authorized
personnel. Operations by unauthorized personnel are limited to flipping circuit breakers
inside the cabinet on and off. Turn circuit breakers for the individual winches on and off to
control the winches. The door to the cabinet must be closed at all times when no work is
being performed inside the cabinet.

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Figure 3: Main cabinet with panel of switches on the outside, allowing for manual operation of winches.

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Figure 4: Winch installed on floating collar.

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Frequency converters. These

must NOT be touched by
unauthorized personnel.

Master
circuit
Circuit

Figure 5: Main cabinet inside.

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3.1 Remote control

Technical specifications

The set consists of a rechargeable AQL transmitter, combined with an AQL receiver with 22
different functions.

• Rechargeable transmitter with IP 67.

• Backlit keyboard
• Range up to 700m in open field

All switches on main cabinet must be in the off position when the remote control is used.

Please note: Does not float!

Figure 6: Remote control.

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Signal cables from the main cabinet are connected inside the connection cabinet.

PRECAUTION:

Repairs and modifications inside the connection cabinet must be performed by authorized
personnel. Unauthorized personnel may only connect signal cables to connection points
inside the connection cabinet. The door to the cabinet must be closed at all times when
signal cables are not connected.

Connection points for signal cables

Figure 7: Connection cabinet inside.

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4. Preventive measures and use

Perform weekly visual inspections of the units, paying particular attention to defects on
cables, ropes, nuts and bolts.

Make sure there is sufficient slack in the electric cable to the connection box.

4.1 Rope replacement

1. Feed the end of the rope through the hole on the drum, leaving approx. 30cm. Wind
the rope around the drum once and splice the loose end of the rope back into itself.
2. Pull the rope until the splice is smooth and even.
3. Then pull the rope around, so that the splice sits inside the drum, see picture below.
4. Turn the drum and feed the rope evenly onto the drum.
5. Maintain moderate tension on the rope while spooling the rest of the rope onto the
drum. Make sure that the layers are spooled evenly onto the drum, as this will reduce
damage to the lower layers of rope when there is a load on the rope.
6. Avoid spooling rope onto the drum at an angle greater than 15° in relation to the
winch. This reduces wear on the rope.

Figure 8: Rope installed on drum.

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5. Using the Aqualine Midgard winch system

PLEASE NOTE:
When lowered/lifted, the sinker tube will move at a speed of approx. 1m/min.
The sinker tube’s circumference, in relation to the position of the winches on the floating
collar, may lead to variations in the distance between the floating collar and the sinker tube
when the sinker tube is in the top position.

Avoid storing the sinker tube in the top position, and when using winches. Please see the
user manual for the Aqualine sinker tube system.

5.1 Preparations for use

• Place the main cabinet so that signal cables can reach the connection cabinet with
sufficient slack.
• The main cabinet must NEVER be placed on the cage and/or be suspended from a
crane.
• Signal cables must be connected to the correct connection point in the connection
cabinet, see tags.
• Main power cable must be connected to power point or generator.
• Activate master circuit breaker in main cabinet and make sure all circuit breakers are
in the ON position.
• Make sure that the EMERGENCY STOP switch on the outside has not been
activated.
• Push the RESET button (blue switch) on the outside of the cabinet to activate the
cabinet.
• To operate winches manually, activate rocker switches on the outside of the main
cabinet for the winches in question.
• When remote control operation is used, deactivate all rocker swithces on the outside
of the main cabinet.
• When using remote control operation, activate the remote control.

The winches are now ready for use.

5.2 Lowering the sinker tube using winches

• Install the net in accordance with the user manual. (See user manual for Aqualine
Sinker tube system and Aqualine Nets)
• When lowering the sinker tube to the operating position, the sinker tube suspension
between winches must be released, so they cannot interfere with the sinker tube
during the lowering process.
• Lower the sinker tube using all of the winches, to avoid subjecting the sinker tube to
uneven loads.
• Make sure nothing interferes with the netting sinking freely during the lowering
operation.
• Lower the sinker tube until there is slack in all winch ropes.

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• There must be at least 70 cm slack in all winch ropes when the sinker tube is in
operating position.
• Adjust the sinker tube suspension between winches to the equivalent slack (min. 70
cm).

• Due to tension in the ropes on the net and, if relevant, the sinker tube drifting due to
ocean currents, you may find that the slack in the winch and suspension ropes no
longer is 70 cm or more. We therefore recommend inspecting the system and making
sure the slack in all winch and sinker tube suspension ropes is at least 70 cm approx.
1 day after lowering the sinker tube.

The sinker tube has now been successfully lowered.

5.3 Lifting the sinker tube using winches

• Prepare the winches for use in accordance with chapter 5.1.
• Start the lifting process using all winches to avoid subjecting the sinker tube to
uneven loads.
• Make sure that the net is not pinched during the lifting process. If necessary, take
breaks in the lifting process to eliminate slack in the netting.
• When the sinker tube approaches the floating collar, an operator must ensure that the
sinker tube does not come into contact with the floating collar. If there are
irregularities, stop/deactivate winches individually to adjust.
• Adjust the sinker tube to the preferred level.
• Tighten the sinker tube suspension system between the winches and distribute the
load from the sinker tube to these using the winches.

The sinker tube has now been successfully lifted.

5.4 Disconnection after use

• Press the EMERGENCY STOP switch on the outside of the main cabinet.
• Disconnect signal cables from the connection cabinet. Make sure all lids and covers
on the connection cabinet are closed.
• Make sure that the caps on the signal cables are closed. The connection points on
the signal cables must not be allowed to fall into the sea or otherwise be submerged
in water.
• Disconnect the main power supply.
• The main cabinet and associated cables must be stored under appropriate conditions
when not in use.

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6. Revision history – User manual

- REV.24/08/2018 Text and figures/pictures revised in their entirety.

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