Wahlberg Winch 10 User manual

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Winch 10
Item No .241
User Manual

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805.241.011 Date: March 22rd, 2017
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 sever 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> approved or equivalent.
Use only Neutrik powerCON TRUE1 NAC3FX-W cable connectors to connect to power
input sockets. Use only Neutrik powerCON TRUE1 NAC3FX-W cable connectors to
connect to power throughput sockets.
Assembly power supply cables following the instructions in this manual only (see page
11).

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805.241.011 Date: March 22rd, 2017
Before each use
Inspect the entire length of the wire rope for bends,
damage, wear, cut cord, corrosion and abuse.
Inspect the wire ferrule crimp and thimble for
damage, wear, corrosion or abuse.
Check all limit switches.
Check the slack detection device
Check the emergency stop (if enabled).
Check that the wire is winded neatly on the drum.
Warning! Do not use the winch if any damage or error is
found!
Isolate the winch from power immediately of 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 they support
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 9.
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 9.
If possible, allow enough clearance beneath the winch so it cannot cause any danger to
personnel beneath it. Else, adjust the lower limit accordingly following the instructions in
this manual.
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.
Inspection
points
Intact wire
Broken wire

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805.241.011 Date: March 22rd, 2017
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.

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805.241.011 Date: March 22rd, 2017
Index
SAFETY INFORMATION 2
INDEX 3
TECHNICAL SPECIFICATIONS 6
INTRODUCTION 7
PACKAGE CONTENT ...................................................................................................................................... 7
DESCRIPTION............................................................................................................................................... 7
AREA OF USE............................................................................................................................................... 8
USING FOR THE FIRST TIME ............................................................................................................................ 8
PHYSICAL INSTALLATION 9
FASTENING THE WINCH TO A FLAT SURFACE ...................................................................................................... 9
MOUNTING THE WINCH ON A TRUSS ............................................................................................................... 9
AC POWER 10
POWER VOLTAGE ....................................................................................................................................... 10
POWER CABLES AND POWER PLUG ................................................................................................................ 10
INSTALLING A POWER INPUT CONNECTOR ON A POWER CABLE ........................................................................... 11
DATA LINK 13
TIPS FOR RELIABLE DATA TRANSMISSION ........................................................................................................ 13
CONNECTING THE DATA LINK........................................................................................................................ 13
SETUP 13
COUNTERBALANCE..................................................................................................................................... 14
MODE SETTING ........................................................................................................................................ 14
DMX ADDRESS SETTING ........................................................................................................................... 16
MANUAL RESET ......................................................................................................................................... 17
POSITIONING............................................................................................................................................. 18
RE-CALIBRATING OVERLOAD ........................................................................................................................ 18
SYNCHRONIZED MOVEMENTS OF MULTIPLE WINCHES....................................................................................... 18
CONTROLLING THE TOP-AND BOTTOM POSITIONS ........................................................................................... 19
SERVICE AND MAINTENANCE 20
MAINTENANCE PLAN .................................................................................................................................. 20
ON-SITE SERVICE........................................................................................................................................ 21
LIFE OF THE WIRE....................................................................................................................................... 21
SPARE PARTS............................................................................................................................................. 21
WIRE DEFECT ............................................................................................................................................ 22
CHANGING WIRE........................................................................................................................................ 23
APPLYING WIRE ......................................................................................................................................... 26
POWER DEFECT.......................................................................................................................................... 26
WINCH 10 - CHEAT SHEET 27

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805.241.011 Date: March 22rd, 2017
Technical specifications
Model: Winch 10
Item no.: .241
Dimensions: 240 × 210 × 150 mm. / 9.5 × 8.3 × 5.19 in. (L×W×H)
(Without mounting clamp)
Power supply: 230 V AC 50 Hz (optional 120V/60Hz).
Power consumption: Max 200 Watt.
Power plug: Neutrik powerCON TRUE1 NAC3FX-W
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 lbs.)
Lifting speed: Variable, 5-30 cm/sec. (2-11.8 inch/sec.)
Lifting wire: 2 mm galvanized steel wire, 8mm snap hook.
Minimum breaking load (wire): 240 kg
Wire fleet angle: None
Minimum load: 0.4 kg (0.88 lb)
Maximum load: 10.0 kg (22.0 lb)
Noise emission: ~55 dB
Weight: 5.2 kg (11.5 lb)
Mounting clamp: Slim eye coupler (Max load: 300 kg) 50 mm (2 inch)
Motor: 24 V DC, 28.9 W, IP30
Maximum expected wire lifetime:
At 2.5 kg load Up to 80,000 cycles running up and down.
At 5.0 kg load Up to 20,000 cycles running up and down.
At 10 kg load Up to 15,000 cycles running up and down.

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805.241.011 Date: March 22rd, 2017
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× Winch10
1× Manfrotte Slim coupler
1× Mounting bolt, nut, and washers (M12) for slim coupler mounting
1× PowerCon Male plug for power cable
1× 8 mm snap hook
1x Instruction manual
Description
Winch 10 is a mini 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 maximum load of 10 kg up and
down. The standard lifting height is 10 m, but it can be extended to 15 m without further risks.
Contact Wahlberg Motion Design for extending your lifting height. The lifting speed is between 5
cm/s and 30 cm/s.
The winches are easily connected as a chain, allowing for advanced and creative ways of making
dynamic movements. The winch is controlled by the DMX channels from the lighting desk. It has
a built-in positioning system which is utilized in locating the desired position. The positioning
system is controlled from a 16 bit DMX channel and is highly accurate; the winch stops within 15
mm. The speed of the winch is likewise controlled from the lighting desk, and it is possible to set
the upper and lower limits of the movement of the winch, adjusting its span of motion. Seven
DMX channels controls the wanted position and the speed of the movement, and the winch
finds the position applied on the lighting desk. The movements are programmed as lighting and
in interaction with the light.
The steering system ensures that the motor only is powered when:
The steering signal is reliable.
The position and speed control is on.
The motor position is calculated after witch a PID regulator calculates the motor speed
and distance.
No overload.
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 on the main. After power
failure the start position of the winch needs to be reset before the winch can function again.
Manually operation of the winch is only intended for mounting, service, and tests.

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805.241.011 Date: March 22rd, 2017
Area of use
The Winch is intended for indoor use only. It is designed for lifting and lowering material at the
weight and speed stated in "Technical Data". 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 customers' responsibility that any local restrictions concerning the use of the winch are
complied with.
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!
Using for the first time
Important! The winch 10 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 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 drawing the power from a mains power
outlet, install a suitable power plug on the power cable.

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805.241.011 Date: March 22rd, 2017
Physical installation
Warning! The Winch 10 must be either fastened to a flat surface such as a roof, or clamped to
a truss or similar structure in such a way that the wire exit points downwards. Do not apply
power to the Winch 10 if it is not securely fastened.
Fastening the winch to a flat surface
The Winch 10 can be fastened to flat surface such as a roof. Check that the surface can support
at least 10 times the weight of all winches and equipment to be installed on it.
Warning! The supporting surface must be hard and flat. Fasten the winch securely.
Mounting the winch on a truss
The Winch 10 can be clamped to a truss or similar rigging structure.
Warning! Use only the supplied rigging clamp and M12 bolt. The clamp must be screwed into
the central hole in the winch’s mounting bracket using the supplied M12 washers and M12
locking-nut.
To clamp a Winch 10 to a truss:
1. Check that the rigging clamp is undamaged and that the
rigging structure can support at least 10 times the
combined weight of all Winches and equipment to be
installed on it.
2. Use the supplied rigging clamp or contact Wahlberg
Motion Design for a replacement.
3. Fasten the clamp to the winch with the supplied M12 bolt,
nut, and washers in the hole in the mounting clamp of the
winch.
4. Block access under the work area. Working from a stable
platform, hang the winch on the truss with the wire
downwards. Tighten the rigging clamp.

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805.241.011 Date: March 22rd, 2017
AC power
Warning! Read “Safety Information” on page 2 before connecting the winch 10 to AC mains
power.
Warning! For protection from electric shock, the Winch 10 must be grounded (earthed). The
power distribution circuit must be equipped with a fuse or circuit breaker and ground-fault
(earth-fault) protection.
Warning! Socket outlets or external power switches used to supply the Winch 10 with power
must be located near the winch and easily accessible so that the winch can easily be
disconnected from power.
Power voltage
Warning! Check that the voltage range specified on the winch’s serial number label matches
the local AC mains power voltage before applying power to the winch. Do not apply AC mains
power to the winch at any other voltage than that specified on the winch’s serial number
label.
Power cables and power plug
The Winch 10 requires a power input cable with a Neutrik powerCON TRUE1 NAC3FX-W cable
connector for AC mains power input. The cable must meet the requirements listed under
“Protection from electric shock” on page 2.
Wahlberg Motion Design can supply the PowerCON input connector without a cable.
If you install a power plug on the power cable, install a grounding-type (earthed) plug that is
rated 20 A minimum. 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
Conductor
Symbol
Screw (US)
Brown
Live
L
Yellow or brass
Blue
Neutral
N
Silver
Yellow/green
Ground (earth)
or
Green