Wahlberg 255.700 User manual

WWW.WAHLBERG.DK
JENS JUULS VEJ 1
TELEPHONE: [phone] VIBY
EMAIL: [email protected]
DENMARK
AC Motor Controller Series
Item No. 255.700 and 255.701
User Manual
AC Motor Controller 550 W No. (255.700)
AC Motor Controller 3000 W No. (255.701)

255.805.001 2 Date: 2021-03-12
Safety Information
WARNING! Read this manual before installing, powering or servicing the product; follow the
safety precautions listed below and observe all warnings in this manual and printed on the
product. If you have questions about how to operate the product, please contact you Wahlberg
Motion Design supplier or Wahlberg Motion Design.
The following symbols identify important safety information on the product and in this manual.
DANGER!
Safety hazard
WARNING!
Moving parts
can crush and
cut
DANGER!
Risk of
electric shock
WARNING!
Risk of fire
WARNING!
Hot surface
WARNING!
See manual
GENERAL PRECAUTIONS
 This product is for professional use and presents risks for sever injury or death.
 Always warm-up electronic equipment to room temperature before applying power.
 Isolate the product from power immediately if defective or showing signs of overload.
Do not reapply power until repairs have been completed.
 Do not modify the product in any way not described in this manual.
 Refer any service operation not described in this manual to a qualified technician.
 Install only genuine Wahlberg parts.
PROTECTION FROM INJURY
 Fasten the product securely to a fixed surface, rig, or structure as described in this
manual.
 Ensure that any supporting hardware can hold at least 10 times the weight of all the
devices they support.
 Block access below the work area whenever installing or servicing the product.
 Do not use the product to lift people or animals and do not exceed the load limits.
 Do not use the product to lift anything over the head of people.
 When the product is installed and may not be used for some time, inspections and
maintenance according to this manual shall always be followed.
PROTECTION FROM ELECTRIC SHOCK
 Do not expose the product to rain or moisture.
 Use an AC power source with overload and ground(earth)-fault protection.
 Disconnect from AC power before servicing.
PROTECTION FROM BURNS AND FIRE
 Do not operate the product if the ambient temperature (Ta) exceeds 40° C (104° F).
 The exterior of the product becomes warm during use. Avoid contact by persons and
materials. Allow the product to cool for at least 10 minutes before handling.
DISPOSING OF THIS PRODUCT
Wahlberg Motion Design products are supplied in compliance with Directive 2012/19/EU of the
European Parliament and of the Council of the European Union on WEEE (Waste Electrical and
Electronic Equipment), including amendments where applicable. Help preserve the
environment! Ensure that this product is recycled at the end of its life. Your supplier can give
details of local arrangements for the disposal.

255.805.001 3 Date: 2021-03-12
Index
SAFETY INFORMATION 2
INDEX 3
TECHNICAL SPECIFICATIONS 4
DRAWING 5
INTRODUCTION 6
PACKAGE CONTENT ...................................................................................................................................... 6
DESCRIPTION............................................................................................................................................... 6
AREA OF USE ............................................................................................................................................... 7
USING FOR THE FIRST TIME ............................................................................................................................ 7
TRANSPORT ................................................................................................................................................ 7
PHYSICAL INSTALLATION 8
FASTENING THE PRODUCT TO A FLAT SURFACE................................................................................................... 8
MOUNTING THE PRODUCT ON A TRUSS (TUBE/PIPE) .......................................................................................... 8
CONNECTIONS ............................................................................................................................................. 9
AC POWER 11
VOLTAGE .................................................................................................................................................. 11
POWER CABLES AND POWER PLUG ................................................................................................................ 11
INSTALLING A POWER INPUT CONNECTOR ON A POWER CABLE ........................................................................... 11
DATA LINK 12
TIPS FOR RELIABLE DATA TRANSMISSION ........................................................................................................ 12
CONNECTING THE DATA LINK ........................................................................................................................ 12
EMERGENCY STOP (OPTIONAL) 13
ENCODER (OPTIONAL) 13
HARD LIMITS 14
AUXILIARY (FUTURE USE) 14
MOTOR 15
INSTALLING A MOTOR OUTPUT CONNECTOR ON A MOTOR CABLE ........................................................................ 15
BRAKE (OPTIONAL) 15
INSTALLING A BRAKE OUTPUT CONNECTOR ON A BRAKE CABLE ........................................................................... 15
SETUP 16
POWERING-UP .......................................................................................................................................... 16
MENU SETTING .......................................................................................................................................... 17
MENU STRUCTURE ..................................................................................................................................... 18
ADJUSTABLE PARAMETERS ........................................................................................................................... 21
DETAILED EXPLANATION OF PARAMETERS ....................................................................................................... 21
MODE SETTING .......................................................................................................................................... 25
DMX CHANNEL OVERVIEW .......................................................................................................................... 26
GETTING STARTED WITH THE AC MOTOR CONTROLLER .................................................................................... 28
LED FUNCTIONS ........................................................................................................................................ 30
ERROR AND ERROR CODES ........................................................................................................................... 30
SERVICE AND MAINTENANCE 31
SPARE PARTS ............................................................................................................................................. 31
ON-SITE SERVICE ........................................................................................................................................ 31
MAINTENANCE PLAN .................................................................................................................................. 31
CHECKLIST ................................................................................................................................................ 32
APPENDIX 1 – DIMENSIONS 33
APPENDIX 2 – POWER & BRAKE CONNECTOR 35
APPENDIX 3 – MOTOR CONNECTOR 37
APPENDIX 4 – BLOCK DIAGRAM 38
AC MOTOR CONTROLLER – CHEAT SHEET 40

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Technical specifications
Model: AC Motor Controller Series
Item no.: 255.700 (550 W) and 255.701 (3000 W)
Dimensions: (L×W×H)
550 W (255.700) 280 x 162 x 137 mm (11 x 6.4 x 5.4 in)
3000 W (255.701) 400 x 207 x 138 mm (15.7 x 8.1 x 5.4 in)
Power supply:
550 W (255.700) 208-240 VAC 50/60 Hz (1P+N+PE)
3000 W (255.701) 380-415 VAC 50/60Hz (3P+N+PE)
Power consumption:
550 W (255.700) 600 W (2,9-2,5A)
3000 W (255.701) 3050 W (9,6A)
Power inlet:
550 W (255.700) Neutrik powerCON TRUE1 NAC3PX (F/M)
3000 W (255.701) CEE 16A (M)
DMX control signal: DMX 512 1990 + DMX512A / 4, 6 or 10 channel modes.
DMX connection: 5 pole XLR (F/M)
Other control inputs: 3-4-5 pole XLR (F) Encoder, Emergency, Limit and AUX
Motor output: Harting HAN A 3P (F/M included)
Brake Connection: Neutrik powerCON TURE1 NAC3FPX (F)
Speed: 0-5000 rpm (depending on motor and gear)
Noise emission: 46 dB @ 1m (3.3 ft)
Ambient temperature: 5-40°C (41-104°F)
Weight:
550 W (255.700) 3 kg (6.6 lb)
3000 W (255.701) 5 kg (11 lb)
Mounting: 2xø12,5mm (0.49 in) and 4xø6,5mm (0.26 in) hole
Motor:
Rating:
550 W (255.700) 208-240VAC/Max. 0.75HP/2.8A/550 W
3000 W (255.701) 380-415VAC/Max. 4HP/7.6A/3000 W
Type: Connect 3 phase motor (∆/Υ depending on motor rating)
Brake: Connect 1 phase brake 220-240VAC/Max. 3.0A
Duty-cycle: 100%

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Drawing
AC Motor Controller 550 W (255.700)
More detailed drawings can be found in Appendix 1 on page 33
AC Motor Controller 3000 W (255.701)
More detailed drawings can be found in Appendix 1 on page 33.

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Introduction
Thank you for selecting the AC Motor Controller Series, a DMX controlled AC frequency inverter
from Wahlberg Motion Design. Before using the product for the first time, please read this
manual carefully. Failure in handling can cause injury of persons and/or damage the product.
Package content
1× AC Motor Controller
1× powerCon TRUE1 female plug NAC3FX-W for power cable (255.700/550 W only)
1x Harting HAN A 3P male connector for motor cable with PG11 cable gland (metal)
1x User Manual
1x Cheat sheet
Description
The product is for stage use, mainly for use in theatres, shows, and concerts. It controls 3 phase
AC motors (not included) to move props and small set pieces or similar in and out of the stage
sphere with a motor rating up to 4HP. Multiple products may easily be connected as a chain,
allowing for advanced and creative ways of making dynamic movements.
The product is controlled through 4, 6 or 10 DMX channels from a lighting desk, where the
position and speed can be changed live or pre-programmed as wished. Through the lighting desk
the top and bottom positions can also be set. However, several hardware options are available
to meet the specific application e.g. using an external encoder, applying external switches to
limit the movement, and using an AC motor brake when the gear is not dynamic self-locking with
the applied load.
Safety functions
The control system ensures that the motor is only powered when:
 The DMX signal is reliable.
 The motor enable channel is in the operation range.
 The speed control channel is on (more than 0%).
 The motor is instructed to move.
 No overload.
 The Emergency input is active and enabled
The product should only be operated by an experienced lighting-desk-operator. The lighting desk
must be programmed according to the manual, so the unit will stop when the speed is put to 0
%. It is also possible for the user to stop the product by disconnecting the mains power, provided
a brake is installed correctly or the gear is dynamic self-locking. After Power interruption the
motor enable channel shall be pullet to 0% and back to the enable range before the product can
function again.

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Area of use
For indoor use only!
WARNING! To reduce the risk of electric shock or injury: use indoors only
WARNING! To reduce the risk of electric shock, do not expose to rain: store indoors!
The product is intended for indoor use only. It is designed for controlling a 3 phase AC motor as
stated in "Technical Data". Any other use of the product may result in a risk of injury of persons
or equipment damage.
Exceeding the inverter load rating may cause failure of the equipment.
Do not modify the product. For any modification contact Wahlberg Motion Design.
It is the customers' responsibility that any local restrictions concerning the use are fulfilled.
Using for the first time
Important! The product must be protected from environmental factors such as physical shocks
and vibration during transportation and storage.
WARNING! Read “Safety Information” on page 2 before installing, powering, operating, or
servicing the product. Before applying power to the unit:
 Check the Wahlberg Motion Design website at www.wahlberg.dk for the most recent
documentation and technical information about the product. Wahlberg user manual revisions
are identified by the revision number in the bottom of each page.
 Carefully review the “Safety Instructions” on page 2.
 Check that the local AC mains power source is within the voltage and frequency ranges
specified on the product.
 See “Power cables and power plug” on page 11. Install a Neutrik powerCON TRUE1 NAC3FX-W-
TOP (255.700) or the CEE 16A (255.701) power input connector on a suitable power cable. If
using the power from a mains power outlet, install a suitable power plug on the power cable.
Transport
Important! The product must be protected from environmental factors such as physical shocks
and vibration during transportation.
Use only the original packaging or flight case for protecting the product during transport.
Contact Wahlberg for enquiries regarding flight cases.

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Physical installation
WARNING! The product must be either fastened to a flat surface such as a roof or clamped to
a truss or similar structure. Do not apply power if it is not securely fastened.
WARNING! The supporting surface must be hard and flat. Fasten the product securely.
WARNING! When the unit is installed in a location where it may cause injury or damage if it
falls, install a secondary suspension such a BGV C1/DGUV 17 safety cable using one of the
12.5mm (0.49 in) holes and fasten it securely around the truss/pipe.
Fastening the product to a flat surface
The product can be fastened to flat surface such as a roof. Check that the surface can support at
least 10 times the weight of all products and equipment to be installed on it, and that the
installation respects all locally applicable regulations.
Mounting the product on a truss (tube/pipe)
The unit can be clamped to a truss or similar rigging structure.
To clamp a product to a truss (tube/pipe):
1. Check that the rigging clamp is undamaged and that the rigging structure can support at
least 10 times the combined weight of all products and equipment to be installed on it.
2. Use the suitable rigging clamp or contact Wahlberg Motion Design for a replacement.
3. Fasten the clamp to the unit with the supplied M12 bolts, nuts, and washers in the hole of
the mounting clamp on the unit.
4. Block access under the work area. Working from a stable platform, hang the product on
the truss with the fabric downwards. Tighten the rigging clamp.
5. Install a suitable safety cable when the product is hanging over-head.
Safety Cable
Half
-
coupler

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Connections
Model: 550 W (255.700)
The below shows the possible connections to the AC motor controller and in the following
sections each of the connection will be explained in detail.
Quick overview of the pinout as shown on the front panel. For further guidance see also
Appendix 4 – Block Diagram on page 38.

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Model: 3000 W (255.701)
The below shows the possible connections to the AC motor controller and in the following
sections each of the connection will be explained in detail.
Quick overview of the pinout as shown on the front panel. For further guidance see also
Appendix 4 – Block Diagram on page 38.

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AC Power
WARNING! Read “Safety Information” on page 2 before connecting the product to AC mains
power.
WARNING! For protection from electric shock, the unit must be grounded (earthed). The
power distribution circuit must be equipped with a fuse or circuit breaker and ground-fault
(earth-fault) protection.
Voltage
WARNING! Check that the voltage range specified on the products serial number label
matches the local AC mains power voltage before applying power. Do not apply AC mains
power to the unit at any other voltage than specified on the serial number label.
Power cables and power plug
The product requires a power input cable with a Neutrik powerCON TRUE1 NAC3FX-W (255.700)
or CEE 16A (255.701) cable connector for AC mains power input. The cable must be rated 20 A
minimum, have three (255.700) or five (255.701) conductors 1.5 mm2 (AWG16) minimum
conductor size and an outer cable diameter of 6-16 mm (0.24-0.47 inch). Cables heat-resistant to
90°C (194°F) minimum. In the EU the cables must be <HAR> approved or equivalent and in the
USA minimum hard usage type (SJT or equivalent).
If you install a power plug on the power cable, install a grounding-type (earthed) plug that is
rated 20 A for USA and 16A for Europe. Follow the plug manufacturer’s instructions. Table 1
shows standard wire color-coding schemes and some possible pin identification schemes; if pins
are not clearly identified, or if you have any doubts about proper installation, consult a qualified
electrician.
Table 1 - Colour guide
Wire Colour (EU) Conductor Symbol Screw (US)
Wire Colour
(US)
Brown Line (1) L (1) Yellow or brass Black
Black Line 2 L2 Yellow or brass Red
Grey Line 3 L3 Yellow or brass Blue
Blue Neutral N Silver Grey
Yellow/green Ground (Earth) or Green Green
Installing a power input connector on a power cable
To install a Neutrik powerCON TRUE1 NAC3FX-W-TOP input connector on a power cable for
255.700(550 W), follow the original Neutrik instructions in Appendix 2 on page 35.
Power
L: Line
N: Neutral
: Ground/Earth

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To install a standard CEE 16A input connector on a power cable for 255.701(3000 W) refer to
manufacturer’s instructions provided with the connector or consult an authorized electrician.
Power
L1: Line 1
L2: Line 2
L3: Line 3
N: Neutral
: Ground/Earth
Data link
A DMX 512 data link is required in order to control the product via DMX. The unit has 5-pin XLR
connectors for DMX data input and output. The pin-out on all connectors is pin 1 = shield, pin 2 =
(data -), and pin 3 = (data +). Pins 4 and 5 in the 5-pin XLR connectors are not used or connected
from DMX in to out in this product.
DMX input / output
1: GND
2: Data 1-
3: Data 1+
4: Data 2-
5: Data 2+
The product is subject to the common limit of 32 devices per daisy-chained link. Note that if
independent control of a product is required, it must have its own DMX channels. Motors that
are required to behave identically can share the same DMX channels. To add more motors or
groups of products when the above limit is reached, add a DMX universe and another daisy-
chained link.
Tips for reliable data transmission
 Use shielded twisted-pair cable designed for RS-485 devices: standard microphone cable cannot
transmit control data reliably over long runs. AWG24 cable is suitable for runs up to 100 meters
(328 ft.).
 Never split a DMX line without using an opto-isolated RS-485 splitter/amplifier.
 Terminate the link by installing a termination plug in the output socket of the last product. The
termination plug, which is a male XLR plug with a 120 Ohm, 0.25 Watt resistor soldered between
pins 2 and 3, “soaks up” the control signal so it does not reflect and cause interference. If a
splitter is used, terminate each branch of the link.
Connecting the data link
To connect the unit to data:
1. Connect the DMX data output from the DMX controller to the products male 5-pin XLR
DMX input connector (DMX IN).
2. Connect the (DMX Out) of the product to the DMX input of the next daisy chained
product.
3. Terminate the last product on the link with a 120 Ohm resistor.

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Emergency Stop (Optional)
WARNING! By default, the emergency stop is NOT enabled!
The product can be configured with an emergency stop; by default, the emergency stop is not
enabled.
The DMX control from a lighting desk should always have a set up so there is a button that sets
the speed of the unit in operation to 0%. Normally lighting desks have a “blackout” button that
sets all intensity channels to 0% and this will also cause the motor to stop when assigned
correctly.
If the emergency stop switch is activated the red Error LED will be lit and the screen display
shows: ‘EMERGENCY STOP PRESSED’:
The emergency stop switch is connected to the male 4 pole XLR connector on the unit. Pin 1 and
Pin 4 should be powered with 12-15 Volt DC to enable operation of the unit.
Emergency Stop
1: GND
2: NC
3: NC
4: E-Stop
(12-15VDC)
Encoder (Optional)
The encoder input is used for position feedback from a Tacho sensor that is mechanically
connected to the motor shaft.
A Tacho sensor can be found in many different manufactures and variants when it comes to the
dimensions, attachment and the resolution.
Using mode 3 or 4 with a Tacho sensor feedback connected, a reset of the motor position is
needed at power up, and the reset can simply be done by running the motor forward with
channel 5 until the forward limit switch has been reached; setting channel 5 to 0% then returns
the motor to the start position.
It is also possible to reset the motor position immediately whenever one or more limit switch is
activated during operation, see LIM RESET menu on page 21. for more details.
Encoder
1: GND
2: TACHO 0/A
3: TACHO 1/B
5: +15VDC

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Hard limits (Optional)
These hard limit inputs will stop the motor movement in direction of the respective limit switch.
Placing the limit switches strategic at the outer positions of the maximum operating range forces
the motor to stop in the outer limit positions.
The display will show a message for each of the limit switch in the Control Mode menu. Example
below shows the activated forward limit switch.
This message will not be shown in the expanded view; this is done to be able to see the position
values while resetting, see from page 21.
The limit switch connects to the 4 pole XLR connector.
The limit switch for the forward movement is connected to pin 1 and 2.
The limit switch for the reverse movement is connected to pin 3 and 4.
When the limit switch FWD is disconnected from GND the motor stops the forward motion.
When the limit switch REV is disconnected from GND the motor stops the reverse motion.
Hard limits
1: GND
2: Forward
3: Reverse
4: GND
Auxiliary (Optional)
This connector is for auxiliary functions and custom solutions. It currently has two default
functions:
1. OFF
2. Revolving stage zero point sensor
The zero point sensor is a sensor necessary for revolving stages. It could be an inductive
sensor detecting a bolt in the stage or a reed switch detecting a magnet attached to the
stage. It is active low. This means that when the zero point is met the I/O pin is pulled low.
Otherwise, it should be left floating or pulled to 5V. Assembled zero point sensor can be
purchased separately.
Auxiliary
1: +5V
2: I/O
3: GND

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Motor connection
WARNING! Risk of electric shock; live voltage on motor terminals!
WARNING! Motor connector should not be coupled or decoupled under electrical load!
CAUTION: For optimal EMI performance the shield of the motor cable shall be electrical
connected to both the motor housing and the PG11 sized cable gland on the Harting HAN 3A
connector.
The tree-phased motor shall be connected to the unit on the female 4 pole Harting connector
and depending on the application the motor may usually be connected in the following
configurations.
230VAC / 400VAC motors needs to be connected in Y-formation (star).
440VAC / 600VAC motors needs to be connected in Delta-formation or alternatively Y.
Motor
1: Phase U (L1)
2: Phase V (L2)
3: Phase W (L3)
: Ground / Earth
Cable Gland: Cable Shield
Installing a motor output connector on a motor cable
To install a Harting HAN A 3P output connector on a motor cable, follow the original Harting
instructions in Appendix 3 – Motor Connector on page 37.
Brake (Optional)
WARNING! Risk of electric shock; live voltage on brake terminals!
WARNING! Mixing-up the TURE1 female output connector for brake and daisy-chained
equipment may damage the unit and lead to malfunction of the motor stop capability.
A one-phased motor brake may be connected to the unit on the Neutrik TRUE1 female
connector.
Brake
L: Line
N: Neutral
: Ground / Earth
Installing a brake output connector on a brake cable
To install a Neutrik powerCON TRUE1 NAC3MX-W output connector on a brake cable, follow the
original Neutrik instructions in Appendix 2 on page 35.

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Setup
WARNING! Read “Safety Information” on page 2 before installing, powering, operating, or
servicing the product.
WARNING! Only experienced DMX users should operate the product. Contact Wahlberg for
further information and education on DMX protocol.
Powering-up
By supplying power to the product, the display will display a start-up screen sequence showing
the model name.
Followed by a screen showing the software and hardware version as shown below.
Then a description of how to enter the menu.
When it changes to the following, the unit is ready to be operated:

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Menu setting
Use the buttons on the display to enter and change menu settings
Use the arrows & to go up or down in the menu
Press to set values.
Press to go back one level in the menu
Press and hold both the up and down arrow for 3 second to enter and leave the menu navigation mode,
see page 19 or continue using the control mode as explained on the next page.

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Menu structure
The menu structure is divided into two different areas for safer motor control.
Control mode and expanded view
The display shows:
Shift to next screen by press for 3 sec.
The screen shows the tachometer value for the current position, wanted position, distance and
speed in motor RPM’s.
E.g. the motor is moving with 1750 RPM’s of speed from current position with tachometer value
10.000 and the wanted position has the tachometer value of 24.250:
Shift to next screen by press for 3 sec.
The screen shows the DMX channel values, if e.g. DMX channel 1 is set to 100% and DMX
channel 3 is set to 100%, the screen will show:
When one of the extended modes are selected while holding down the for further 3s will
reveal the extended mode values.
P: Current position (values 0-50.000)
W:
Wanted position (values 0
-
50.000)
D: Distance from current to wanted position
S:
Speed (values from 0
-
maximum motor RPM
setting in operation, and limited to half the
speed during setup)
DMX
channel
1
DMX
channel
2
DMX
channel
3
DMX
channel
4
DMX
channel
5
DMX
channel
6
DMX
channel
7
DMX
channel
8
M1: Refers to the selected operation mode.

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Extended mode = ACCDCC
Shows the acceleration and deceleration of 10%
Extended mode = PIDS
Shows each of the PID values from 0 to 5000 representing a setting of 0-100%.
Holding down the button 5 sec. while these views is shown will save the DMX controlled
values in the memory of the AC motor controller.
This feature is used for easy and fast tuning of the motor control in extended modes, with the
option to return to the default mode with the same performance and safer control in daily use.
Shift back to the previous screens by pressing for 3 sec.
Menu navigation mode
The display shows:
In menu navigate mode, the different parameters can be changed.
In menu navigate mode the motor is stopped, and DMX input has no effect, but the motor can
still be manually controlled by the MAN FWD/REV menu though.
Press the arrows or to go up or down in the menu choices.
The bottom line of the display is showing:
Adjusting menu parameters
The display shows:

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Press to change the DMX ADDR value.
The display shows:
Use the arrows or to adjust the DMX ADDR.
Save changed value
The display shows:
Press to change the top line to:
Then press and hold until the top line of the display(X) counts-up to 20 then shows OK.
The Value is now saved in the memory.