Wahlberg Winch 50 Double User manual

Axel Gruhns Vej 3
DK-8720 Højbjerg
DENMARK
WWW.WAHLBERG.DK
WWW.WAHLBERG.DK · TELEPHONE [phone] · EMAIL: [e-mail]
Winch 50 Double
Item No 246.702
User Manual

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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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−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 4×
Manfrotto slim coupler 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.
Broken wire
Before each use
−Inspect the entire length of the wire rope for bends,
damage, wear, cut cord, corrosion and abuse.
−Inspect the wire wedge clamp for damage, wear,
corrosion or abuse.
−Check that the load is securely mounted
−Check all limit switches.
−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!
Inspection
points
Intact wire

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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
.

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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
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
LIFTING WIRE POWER AND DATA LINK 14
POWER VOLTAGE .................................................................................................................................... 14
LIFTING CABLE CONNECTION PLUG.......................................................................................................... 14
CONNECTING THE POWER CABLE............................................................................................................. 14
EMERGENCY STOP SWITCH (OPTIONAL) 15
ENABLE EMERGENCY STOP........................................................................................................................ 15
LIFTING WIRE POWER 17
POWER VOLTAGE ..................................................................................................................................... 17
LIFTING CABLE CONNECTION PLUG............................................................................................................ 17
CONNECTING THE POWER CABLE............................................................................................................... 17
SETUP 18
COUNTERBALANCE ................................................................................................................................... 18
MENU SETTING......................................................................................................................................... 18
DMX ADDRESS SETTING ......................................................................................................................... 20
ADJUSTING LIMIT SWITCHES...................................................................................................................... 22
ADJUSTABLE PARAMETERS ....................................................................................................................... 22
DETAILED EXPLANATION OF PARAMETERS................................................................................................... 23
NORMAL OPERATION................................................................................................................................ 24
SYNCHRONIZED MOVEMENTS OF MULTIPLE WINCHES................................................................................... 24
LED FUNCTIONS ...................................................................................................................................... 25
SERVICE AND MAINTENANCE 26
MAINTENANCE PLAN................................................................................................................................. 26
CHECKLIST............................................................................................................................................... 27
ON-SITE SERVICE...................................................................................................................................... 27
LIFE OF THE WIRE .................................................................................................................................... 27
WIRE DISCARD CRITERIA ........................................................................................................................... 27
SPARE PARTS ........................................................................................................................................... 28
WINCH 50 - CHEAT SHEET 29

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Technical specifications
Model: Winch 50 Double
Item no.: 246.702
Dimensions: 1644 × 298 × 445 mm / 64.7 × 11.7 × 17.5 in.
(L×W×H)
Power supply: 210-240V AC 50-60 Hz.
Power consumption: 500 Watt.
Power plug: Neutrik powerCON TRUE1 NAC3PX
DMX control signal: DMX 512 1990 + DMX512A / 6 channels used.
DMX connection: 5 pole XLR, male & female
Own weight: 116 kg (255.7 lb)
Lifting height: 42 m (137.8 ft.)
Lifting capacity: 50 kg (110 lb)
Lifting speed: Variable, 0.09-0.45 m/s (3.5-17.7 in/s)
Wire fleet: 535 mm (21.1 in)
Duty cycle: Maximum 30% at max load
Minimum load: 3.5 kg (7.7 lb)
Maximum load: 50.0 kg (110 lb)
Noise emission (at 1 m): ~65 dB
Weight: 30 kg (66.1 lb)
Motor: 230V AC, 0.55 kW 2800 rpm
Lifting wire specifications:
Lifting wire: 6.5 mm 8x19 galvanised steel + 3x0.60 mm2
electrical conductors (EN 12385-5, ISO 4344)
Maximum lifting wire voltage: 230 V
Maximum lifting wire current: 10 A
Wire current inlet Neutrik powerCON TRUE1 NAC3MPX
Wire current outlet/plug Neutrik powerCON TRUE1 NAC3FX
Minimum breaking load (wire): 21.9 kN (2,233 kg / 4,923 lb)
Wire safety factor: minimum 10

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Introduction
Thank you for selecting the Winch 50, 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 50
1 × PowerCon NAC3FX-W female plug for power cable
1 × PowerCon NAC3FX-W female plug for lifting wire power
1 × Instruction manual
1 × Cheat Sheet
Description
Winch 50 is a wire 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 50
kg up and down. The lifting height is 40 m. Contact Wahlberg Motion Design for
extending your lifting height. The lifting speed is between 9 cm/s and 45 cm/s.
The winches are easily connected as a chain, allowing for advanced and creative ways
of making dynamic
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 witch a PID regulator calculates the
motor speed and distance.
•No overload.
Winch 50 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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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 50 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 50. 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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Physical installation
Warning! The Winch 50 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 50 if it is not securely fastened.
Fastening the winch to a flat surface
The Winch 50 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.

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AC power
Warning! Read “Safety Information” on page 2 before connecting the winch 50 to
AC mains power.
Warning! For protection from electric shock, the Winch 50 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 50
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 fixture at any other voltage than that specified on
the winch’s serial number label.
Power cables and power plug
The Winch 50 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. The Neutrik
assembly guide below 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.
By supplying power to the winch, the display will show a start-up screen and then
change to:

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Installing a power input connector on a power cable
To install a Neutrik powerCON TRUE1 NAC3FX-W input connector on a power
Cable, follow the original Neutrik instructions below:

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Data link
A DMX 512 data link is required in order to control the winch via DMX. The Winch 50
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 in the Winch 50 but are available for possible additional data
signals as required by the DMX512-A standard. Standard pin-out is pin 1 = shield, pin 2
= data (-) and pin 3 = data (+).
Pin
DMX IN
DMX OUT
1
GND
GND
2
Data -
Data -
3
Data +
Data +
4
NC
NC
5
NC
NC
The Winch 50 is subject to the common limit of 32 devices per daisy-chained link. Note
that if independent control of a winch is required, it must have its own DMX channels.
Winches that are required to behave identically can share the same DMX channels. To
add more winches or groups of winches 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. 24 AWG cable is suitable
for runs up to 100 meters (328 ft.).
−Never use both a winch’s outputs to split a DMX link. To split the link into branches,
use an opto-isolated RS-485 splitter/amplifier.
−Terminate the link by installing a termination plug in the output socket of the last
winch. 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 Winch 50 to data:
1. Connect the DMX data output from the DMX controller to the Winch 50’s male
5-pin XLR DMX input connector (DMX 512 IN).
2. Connect the DMX output of the winch to the DMX input of the next winch and
continue connecting winches output to input (DMX 512 OUT).
3. Terminate the last fixture on the link with a 120 Ohm resistor.
The DMX lamp is the green led, above the display.
−Glows constant, when the DMX connection is correct.
−Flash if the DMX signal is missing or wrongly connected.

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Lifting wire power and data link
Warning! Read “Safety Information” on page 2 before connecting AC mains power
to the lifting wire.
Warning! Socket outlets or external power switches used to supply the lifting wire
attachment with power must be located near the winch and easily accessible so
that the lifting wire attachment can easily be disconnected from power.
Power voltage
Warning! Check that the voltage range specified in this manual matches the local
AC mains power voltage before applying power to the wire conductors. Do not
apply AC mains power to the wire conductors at any other voltage than those
specified in this manual.
Ratings for lifting wire:
Maximum voltage 240 V
Maximum current 10 A
Lifting cable connection plug
The Winch 50 requires a power input from a Neutrik powerCON TRUE1 NAC3FX-W cable
connector. The cable for connecting the powerCON plug on the winch for the lifting
wire power, must meet the requirements listed under “Protection from electric shock”
on page 2.
The lifting wire has tree conductors.
Connecting the power cable
Refer to the section “AC power” on page 10.for installation of the power connection.
To install a Neutrik powerCON cable connector, follow the original Neutrik instructions
on page 11.

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Emergency stop switch (Optional)
The Winch can be configured with an emergency stop
Warning! By default the emergency stop is NOT enabled!
If the emergency stop switch is activated (pin 1 and pin 4 are disconnected) the red
ERROR
LED will light.
The emergency stop switch is connected to the male 4 pole XLR connector.
Pin 1 and Pin 4 should be powered with 12-15 volt DC to enable the running of the
motor
Pin out:
Pin 1 = GND
Pin 2 = NC
Pin 3 = NC
Pin 4 = 12 – 15 volt DC
Ready to use
When the Winch 50 has been connected to
power, DMX, and an emergency stop
switch, it is ready for use, and can be
controlled from the lighting desk.
Enable Emergency stop
To enable to emergency stop 2 steps are required.
The first step is to set emergency stop in the software to ON.
Access the menu, and find the menu E STOP:
Set E STOP to ON

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Then inside the unit there is an orange wire that needs to be set correctly for
operation with/without emergency stop.
Emergency stop disabled Emergency stop enabled
When the emergency stop is enabled and the little piece of orange wire is not
connected it is recommended that it is secured in some way so it does not hit
anything. Some electrical tape will be enough to keep it in place.

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Lifting wire power
Warning! Read “Safety Information” on page 2 before connecting AC mains power
to the lifting wire.
Warning! Socket outlets or external power switches used to supply the lifting wire
attachment with power must be located near the winch and easily accessible so
that the lifting wire attachment 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.
Lifting cable connection plug
The Winch 50 requires power input via a Neutrik PowerCON True1 cable connector.
The cable for connecting the PowerCON True1 plug on the winch for the lifting wire
power and data, must meet the requirements listed under “Protection from electric
shock” on page 2.
The lifting wire has tree conductors; two for power and one for ground.
Connecting the power cable
Refer to the section “AC power” on page 10Fejl! Bogmærke er ikke defineret. for
installation of the power connection.

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Setup
Warning! Read “Safety Information” on page 2before installing, powering,
operating, or servicing the Winch 50.
Warning! Before running the winch, it is important to put a counterbalance on the
wire.
Warning! Only experienced DMX users should operate the winch. Contact Wahlberg
for further information and education on DMX protocol.
Counterbalance
When the winch has been mounted, it is important to mount a counterbalance before
running with it. This can be done by hanging some sort of weight in the wedge sleeve
at the end of the wire.
Menu setting
The menu structure is divided into two different areas for safer motor control.
Control mode
The display shows:
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, the motor
can be moved by the MAN UP/DWN menu though.
Menu mode change
MENU - NAVIGATE:
The top line of the display is showing:
Push the buttons UP & DOWN and hold them for 3 seconds.
Now the top line of the display should show:

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MENU - DMX CONTROL:
Go back to the starting position and activate DMX control
The top line of the display is showing:
Push the buttons UP & DOWN and hold them for 3 seconds.
Now the top line of the display is showing:
Navigate the menu
The top line of the display is showing:
Push the buttons UP or DOWN to go up and down in the menu choices.
The bottom line of the display is showing:
Adjusting menu parameters
The display shows:
Push ENT to change the DMX ADDR value.
The display shows:

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Use the arrows ↑and ↓to adjust the DMX ADDR.
Save changed value
The display shows:
Push ENT to change the top line to:
Where X is an increasing number from 1 to 20.
Then press and hold ENT
The top line of the display counts up to 20 then shows OK.
The Value is now saved in the memory.
DMX ADDRESS setting
The DMX address, also known as the start channel, is the first channel used to receive
instructions from the controller. For independent control, each winch must be assigned
its own control channels.
The DMX address is configured using the three DMX ADDRESS selectors on the winch.
The selected DMX address states from which channels, on the lighting desk, the
winch is controlled. The DMX address can be selected from 1 – 506. The Winch 50 uses
6× DMX channels.