Wahlberg 241 User manual

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Winch 10
Item No 241
User Manual

241.805.012 2 Date: 2017-10-24
Safety Information
The following symbols are used to identify important safety information on the product
an in this manual:
This product is for professional use only. It is not for household use.
This product presents risks for severe injury or death due to fire hazards, electric
shock, and falls.
Read this manual before installing, powering or servicing the winch; follow the safety
precautions listed below and observe all warnings in this manual and printed on the
winch. If you have questions about how to operate the winch safely, please contact
you Wahlberg Motion Design supplier or Wahlberg Motion Design.
PROTECTION FROM ELECTRIC SHOCK
−Disconnect the winch from AC power before removing or installing any cover or
part and not when in use.
−Always ground (earth) the winch electrically.
−Use only a source of AC power that complies with local building and electrical
codes and has both overload and ground-fault (earth-fault) protection.
−Before using the winch, check that all power distribution equipment and cables
are in perfect condition and rated for the current requirements of all connected
devices.
−Power input throughput cables must be rated 20 A minimum, have three
conductors 1.5 mm2(AWG16) minimum conductor size and an outer cable
diameter of 5-15 mm (0.2-0.6 inch). Cables must be hard usage type (SJT or
equivalent) and heat-resistant to 90°C (194°F) minimum. In the EU the cables
must be <HAR> or equivalent.
−Use only Neutrik powerCON TRUE1 NAC3FX-W cable connectors to connect to
power input sockets. Use only Neutrik powerCON TRUE1 NAC3MX-W cable
connectors to connect to power throughput sockets.
−Assembly power supply cables following the instructions in this manual only (see
page 13).

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−Isolate the winch from power immediately if the power plug or any seal, cover,
cable, or other component is damaged, defective, deformed, wet, or showing
signs of overheating. Do not reapply power until repairs have been completed.
−Do not expose the winch to rain or moisture.
−Refer any service operation not described in this manual to a qualified
technician.
PROTECTION FROM BURNS AND FIRE
−Do not operate the winch if the ambient temperature (Ta) exceeds 40°C (104°F).
−The exterior of the winch becomes warm during use. Avoid contact by persons
and materials. Allow the winch to cool for at least 10 minutes before handling.
−Do not modify the winch in any way not described in this manual.
−Install only genuine Wahlberg parts.
PROTECTION FROM INJURY
−Fasten the winch securely to a fixed surface, rig, or structure when in use. The
winch is not portable when installed.
−Ensure that any supporting structure and/or hardware can hold at least 10 times
the weight of all the devices including their load.
−If suspending from a rigging structure, fasten the winch using the supplied
Manfrotto slim coupler and M12 bolt, nut, and washers supplied with the winch
according to the manual, see page 11.
−Always install the winch as described in this manual. If the winch is installed in a
location where it may cause injury or damage if it falls, install as described in
page 11.
−If possible, allow enough clearance beneath the winch so it cannot cause any
danger to personnel beneath it.
−Check that all external cobblers and rigging hardware are securely fastened.
−Block access below the work area and from a stable platform whenever installing,
servicing or moving the winch.
−Do not operate the winch with missing or damaged covers, shields, or wire.
−Do not use the winch over the head of people
−Do not use the winch to lift people or animals.
−Only use the winch to lift static loads.
Inspection
points
Intact wire
Broken wire
Before each use
−Check that the winch is safely and correctly installed/mounted.
−Inspect the entire length of the wire rope for bends, damage
and wear, cut cords, corrosion and abuse.
−Inspect the wire ferrule crimp and thimble for damage, wear,
corrosion or abuse.
−Secure that the load is safely attached and weighs maximum 10
kg (22.0 lb).
−Check all limit switches
−Check the slack detection device
Warning! Do not use the winch if any damage or error is found!

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Disposing of this product
Wahlberg Motion Design products are supplied in compliance with Directive
2002/96/EC of the European Parliament and of the Council of the European
Union on WEEE (Waste Electrical and Electronic Equipment), as amended
by Directive 2003/108/EC, 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 of Wahlberg Motion Design products.

241.805.012 5 Date: 2017-10-24
Index
SAFETY INFORMATION 2
INDEX 4
TECHNICAL SPECIFICATIONS 6
DRAWING 7
INTRODUCTION 8
PACKAGE CONTENT .........................................................................................8
DESCRIPTION................................................................................................8
SAFETY FUNCTIONS .........................................................................................8
AREA OF USE................................................................................................9
USING FOR THE FIRST TIME..................................................................................9
TRANSPORT................................................................................................10
PHYSICAL INSTALLATION 11
FASTENING THE WINCH TO A FLAT SURFACE ................................................................11
MOUNTING THE WINCH ON A TRUSS ........................................................................11
MOUNTING THE LOAD ......................................................................................12
AC POWER 13
POWER CABLES AND POWER PLUG ..........................................................................13
INSTALLING A POWER INPUT CONNECTOR ON A POWER CABLE...............................................13
DATA LINK 14
TIPS FOR RELIABLE DATA TRANSMISSION ....................................................................14
CONNECTING THE DMX ....................................................................................14
SET UP 15
BLOCK DIAGRAM ...........................................................................................15
COUNTERBALANCE -SLACK WIRE ..........................................................................15
CONNECTIONS .............................................................................................15
EMERGENCY STOP..........................................................................................16
MODE SETTING............................................................................................16
DMX ADDRESS SETTING ..................................................................................18
MANUAL RESET.............................................................................................20
POSITIONING...............................................................................................20
RE-CALIBRATING OVERLOAD................................................................................21
SYNCHRONIZED MOVEMENTS OF MULTIPLE WINCHES.........................................................21
CONTROLLING THE SOFT TOP AND BOTTOM LIMITS .......................................................22
SERVICE AND MAINTENANCE 23
PARTS .....................................................................................................23
MAINTENANCE PLAN........................................................................................24
CHECKLIST.................................................................................................24
ON-SITE SERVICE...........................................................................................25
LIFE OF THE WIRE..........................................................................................25
WIRE DEFECT ..............................................................................................26
WIRE DISCARD CRITERIA....................................................................................27
CHANGING WIRE ...........................................................................................28
APPLYING WIRE ............................................................................................33
POWER DEFECT ............................................................................................33
APPENDIX 1 34
APPENDIX 2 35
APPENDIX 3 37
WINCH 10 - CHEAT SHEET 38

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Technical specifications
Model: Winch 10
Item no.: 241
Dimensions (L×H×W): 205 × 224 × 148 mm / 8.1 × 8.8 × 5.8 in
(Without mounting clamp)
Power supply: 230 V AC 50 Hz (optional 120V/60Hz).
Power consumption: Max 120 Watt
Power inlet/outlet: Neutrik powerCON TRUE1 NAC3PX (F/M)
DMX control signal: DMX 512 1990 + DMX512A / 7 channels used.
DMX connection: 5 pole XLR, In & link
Lifting height: 10 m (33 ft.)
Lifting capacity: 10 kg (22 lb)
Lifting speed: Variable, 5-30 cm/s (2-11.8 in/s)
Snap hook: 8 mm (5/16 in) galvanized steel
Capability of overload test: Yes, at 125% of maximum load.
Wire fleet angle: None
Minimum load: 0.4 kg (0.88 lb)
Noise emission: ~55 dB (max measured noise at 1 m/3.3 ft.)
Weight: 5.2 kg (11.5 lb)
Mounting clamp: Slim eye coupler 50 mm (2 in)
Motor: 24 V DC, 28.9 Watt, IP30
Lifting wire specifications:
Lifting wire: 2 mm (5/64 in) 7x7 galv. steel wire (EN 12385-4)
Minimum breaking load (wire): 280 kg (2750 N / 618 lb)
Wire safety factor: minimum 10
Maximum expected wire lifetime:
−At 2.5 kg (5.5 lb) load Up to 80,000 cycles running up and down.
−At 5.0 kg (11.0 lb) load Up to 20,000 cycles running up and down.
−At 10 kg (22.0 lb) load Up to 15,000 cycles running up and down.

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Drawing
More detailed drawings and from more angles can be found in Appendix 1 on page 34.

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Introduction
Thank you for selecting the winch 10, a DMX controlled winch from Wahlberg Motion
Design. Before using the winch for the first time, please read this manual carefully.
Failure in handling can cause injury of persons and/or damage the winch.
Package content
1× Winch 10
1× Manfrotto Slim coupler
1× Mounting bolt, nut, and washers (M12) for slim coupler mounting
1× Neutrik PowerCon NAC3FX-W female plug for power cable
1× 8 mm snap hook
1x User manual
1x Cheat sheet
Description
Winch 10 is a small winch for stage use, mainly for use in theatres, shows, and
concerts. It lifts props and small set pieces in and out of the stage sphere at a
maximum load of 10 kg up and down. Lifting height is 10 meters, and the lifting speed
is from 5cm/s to 30 cm/s.
The winch is controlled by the standard DMX controlling signal, so a normal lighting
desk can be used to control the movement, programmed as normal light.
For a low number of winches, a standard lighting desk can be used, but when many
winches are used, more advanced desks should be used to maintain easy control of the
units.
The Winch 10 uses 7 channels of the DMX-line, and they control the position, speed,
limits, and reset functions.
The Winch 10 has an advanced internal positioning system with 16 bit, used for finding
the position desired by the operator. With a 16 bit positioning channel (ch1 and ch2)
the operator set the desired position, and the winch will run to this position, with the
speed applied on the speed channel (ch3).
With channel 4 and 5 it is possible to set the soft TOP and BOTTOM limits of the winch,
adjusting its span of motion.
Channel 6 and 7 is used for resetting the winch, when powering up.
Multiple winches are easily daisy chained with power in-out and DMX in-Out, allowing
to create advanced and dynamic movements with 100’s of winches working together in
the same installation.
Safety functions
The control system ensures that the motor only is powered when:
•The control signal is reliable.
•The position and speed control is on.
•The motor position is calculated after which a PID regulator calculates the motor
speed and distance.
•No overload.

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Winch 10 should only be operated by an experienced DMX-controlled-lighting-desk-
operator.
The lighting desk has to be programmed according to the manual, so the winch will
stop when the speed is put to 0 %. It is also possible for the user to stop the winch by
disconnecting it from the main. After power failure the start position of the winch
needs to be reset before the winch can function again.
Manual operation of the winch is only intended for mounting, service, and tests.
Area of use
For indoor use only!
Caution! To reduce the risk of electric shock or injury: use indoors only
Caution! To reduce the risk of electric shock, do not expose to rain: store indoors!
The winch is intended for indoor use only. It is designed for lifting and lowering
material at the weight and speed stated in "Technical specifications" on page 6. Any
other use of the winch may result in a risk of injury of persons or equipment damage.
Exceeding the load rating may cause failure of the equipment.
Use only approved rigging connectors to secure the load to the wire and do not wrap
the wire around the load as this will damage the wire and result in a risk of injury of
persons or equipment damage.
Do not modify the winch. For any modification of your winch, contact Wahlberg.
It is the customer's sole responsibility to comply with any relevant local laws,
regulatory requirements, and restrictions, concerning the use of the winch.
Using for the first time
Important! The Winch 10 must be protected from environmental factors such as
physical shocks and vibration during storage.
Warning! Read “Safety Information” on page 2 before installing, powering,
operating, or servicing the winch. Before applying power to the winch:
−Check the Wahlberg Motion Design website at www.wahlberg.dk for the most
recent documentation and technical information about the winch 10. 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 winch power voltage
and frequency ranges.
−See “Power cables and power plug” on page 2. Install a Neutrik powerCON TRUE1
NAC3FX-W 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.

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Transport
Important! The Winch 10 must be protected from environmental factors such as
physical shocks and vibration during transportation.
Before transport, it is important to roll the wire of the winch up till the hard TOP limit
so a maximum of 5 cm (1.9 inch) remains out of the winch. If the wire is loose it may
jump off the wire wheel during transport and cause damage to the winch.
Use only the original packaging, flight case, or pallet frame for protecting the winch
during transport. Contact Wahlberg for enquiries regarding flight cases or pallet
frames.