Wahlberg 245 Winch 50 User manual

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Jaegergaardsgade 160
DK-8000 Aarhus C
DENMARK
WWW.WAHLBERG.DK
Front page 245 Winch 50
User Manual

805.245.005 Date: January 10, 2017
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Contents
GENERAL: ................................................................................................................................................................... 3
PRODUCT CONTENT:................................................................................................................................................... 3
DESCRIPTION: ............................................................................................................................................................. 3
WINCH 50 FEATURES .................................................................................................................................................. 4
DMX CHANNELS USED FOR CONTROLLING THE WINCH................................................................................................................ 4
CONNECTING THE WINCH 50 ...................................................................................................................................... 5
POWER SUPPLY................................................................................................................................................................... 5
DMX ............................................................................................................................................................................... 5
MOUNTING FOR WINCH ....................................................................................................................................................... 5
DMX CONTROL ........................................................................................................................................................... 6
DMX CHANNEL DESCRIPTION ................................................................................................................................................ 7
MENU ......................................................................................................................................................................... 8
CONTROL MODE ................................................................................................................................................................. 8
MENU NAVIGATION MODE.................................................................................................................................................... 8
MENU MODE CHANGE ......................................................................................................................................................... 8
NAVIGATE THE MENU .......................................................................................................................................................... 8
ADJUSTING MENU PARAMETERS............................................................................................................................................. 8
SAVE CHANGED VALUE ......................................................................................................................................................... 8
ADJUSTING LIMIT SWITCHES ...................................................................................................................................... 9
ADJUSTABLE PARAMETERS........................................................................................................................................10
DETAILED EXPLANATION OF PARAMETERS................................................................................................................10
NORMAL OPERATION ................................................................................................................................................11
TEMPERATURES ................................................................................................................................................................ 11
DUTY CYCLE ..................................................................................................................................................................... 11
LIFTING SPEEDS AND WEIGHT............................................................................................................................................... 11
LED FUNCTIONS .........................................................................................................................................................12
DMX LED....................................................................................................................................................................... 12
ERROR LED ..................................................................................................................................................................... 12
ERRORS AND ERROR CODES: .....................................................................................................................................12
INSPECTIONS AND MAINTENANCE: ...........................................................................................................................13
CHEAT SHEET-WINCH 50............................................................................................................................................14
BEFORE USE ..................................................................................................................................................................... 14
DMX CHANNELS............................................................................................................................................................... 14
GETTING STARTED............................................................................................................................................................. 14
EMERGENCY STOP SWITCH (ONLY IN VERSIONS WITH EMERGENCY STOP!) .................................................................................... 14

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Technical specifications:
Item No. : 245
Dimensions : 329 x 298 x 445 mm / 12.9 x 11.7 x 17.5 in. (L-W-H)
Power supply : 210-240V AC 50-60Hz
Power consumption : 500 W
Power plug : Powercon NAC3MPA-1
Control signal : DMX 512
DMX channels : 6 channels.
DMX plug : XLR 5pole Male & Female
Lifting height : 12.5 m. 41 ft.
Lifting capacity : 50 kg. 110 Lbs.
Lifting speed : MIN 0.091m/s; MAX 0.45m/s
Lifting wire : 3 mm galvanized steel wire 19x7, MBL 589 kg.
Min. load : 3.5 kg. 8 lbs.
Wire Fleet : 83mm (3.27 in)
Noise emission : 50 dB 1 meter from the winch
Ambient temperature range : 0 –40 ºC / 32 –104 ºF
Net weight : 30 kg. 66 lbs.
Mounting clamp : 4 x Slim eye coupler (Max load: 300 kg)
Mounted 2x2, 353 x [min 227, max 251]mm (13.9x (8.94,9.88) in)
Motor : 230 V AC, 0.55 kW 2800 rpm

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General:
Before using the winch for the first time, please read the installation- safety- operation- and
maintenance instructions carefully. Failure in handling can cause injury of persons and/or damage
the winch.
Product content:
1 Winch 50
1 Powercon plug for cable
1 Instruction manual
Description:
The Winch 50 is a wire winch for lifting and moving stage objects. It is controlled from the lighting
desk.
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 should be reset.
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."
Attention!
Before using the winch read the users manual paying special attention to the chapter
"Connecting the winch".
It is important to keep the wire in a good condition. See "Maintenance".
Make sure the operator is able to watch the winch while running it in order to
have visual confirmation of the movements.
The winch should only be operated by an experienced DMX-controlled-lighting-desk-operator.
When the winch is used manually, the operator should make sure not to be placed in a hazardous
situation.
Likewise it is the operator's responsibility not to run the winch in a way that brings other persons in
a hazardous situation.

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Winch 50 Features
The Winch 50 is a wire winch for lifting and moving stage objects.
The winch is controlled from the lighting desk so that movements on and off the stage can be
controlled in interaction with the lighting, adding dynamics and diversity to the show.
Winch50 has an advanced positioning system witch is controlled with a 16 bit DMX channel. This
gives a very high accuracy.
The lifting speed is also controlled by DMX, and it is possible to limit the outer ranges of how high
or low the winch can move.
Before the Winch is powered down channel 4 should be set outside the enable area. When it is set
outside this area the current position is saved and when it is powered up no resetting of positions is
needed. If this isn’t done the top position has to be reset using channel 5.
When the winch is powered on it cannot run before DMX channel 4 has been out of the enable area
of 50-55 %.
It is very important that there is a minimum load on the wire, min 3.5 kg.
DMX channels used for controlling the winch
(For a more detailed description see page 6)
DMX channel 1 –Position. (16 bit DMX channel)
DMX channel 2 –Position fine. (16 bit DMX channel)
DMX channel 3 –Maximum speed
DMX channel 4 –Motor Enable –between 50 % and 55 %, to enable the motor output.
DMX channel 5 –Reset UP
DMX channel 6 –Manual DWN, (Sets the TAC RANGE)
Positioning with tacho feedback:
Manual up on channel 5 is active. It is also used for resetting.
Manual down on channel 6 is active.
Resetting the up position:
Run the motor to the top reset position, with channel 5.
Setting DMX channel 5 to 0% resets the position.

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Connecting the Winch 50
Power supply
The Winch 50 must be connected to 208-240VAC.
Power is connected to the yellow Neutric Powercon TRUE1 connector.
By supplying power to the winch, the display will show a startup screen and then change to
DMX CONTROL .
START CHAN 1
DMX
DMX is connected to the male 5-pole XLR connector.
The DMX LED will light constantly when receiving a DMX signal and it will flash when no
DMX is received.
Pinout:
DMX IN DMX OUT
Pin 1 = GND Pin 1 = GND
Pin 2 = Data –Pin 2 = Data –
Pin 3 = Data + Pin 3 = Data +
Pin 4 = NC . Pin 4 = NC.
Pin 5 = NC. Pin 5 = NC.
Mounting for winch
The winch is mounted in 4 slim couplers sitting on the top plate. It is important to use all for slim
couplers for mounting because the load is not evenly distributed across the winch.
Without all 4 mounting points the winch will hang at an angle and have a significantly reduced
lifetime.

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Emergency stop switch (Optional)
The Winch can be configured with an emergency stop
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 Rolldown 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. First in the menu change E STOP to ON.
Secondly 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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DMX Control
When the Winch 50 is connected to power and DMX it is ready for use and can be controlled from
the lighting desk.
DMX channel description
DMX channel 1 –Position. (16 bit DMX channel)
DMX channel 2 –Position fine. (16 bit DMX channel)
DMX channel 3 –Maximum speed
DMX channel 4 –Motor Enable –between 50 % and 55 %, to enable the motor output.
DMX channel 5 –Reset UP
DMX channel 6 –Manual DWN
DMX channel 1 –Position. (16 bit DMX channel)
This channel, together with channel 2, makes up a 16 bit position on the winch.
A high value on channel 1 gives a high position. A low value on channel 1 gives a low
position on the motor.
DMX channel 2 –Position fine. (16 bit DMX channel)
This is the fine position of the winch. This channel, together with channel 1, makes up a 16 bit
position on the motor.
Channel 2 is used to fine-tune the position.
DMX channel 3 –Speed
Channel 3 is used to control the speed or the maximum speed of the winch.
If channel 3 is 0% the motor will not start.
If channel 3 is 50% the motor will run at 50% speed.
DMX channel 4 –Motor Enable 50 % and 55 %, for the motor to turn.
Channel 4 is used as an extra security channel.
The value on channel 4 needs to be between 50 and 55 %, for the motor to run.
All other values make the motor stop and activate the brake.
All other values will also reset any error shown.
All other values will save the current position before a power down.
DMX channel 5 –Reset Up
There is a 3s delay on this channel to reduce risk of accidentally resetting the top position.
Channel 5 is used to manually move the wire up.
When channel 5 is in use it will run the motor Up until it hits the limit switch UP.
Setting DMX channel 5 to 0 resets the position.
10 –100% makes the motor run up, at variable speed.
(10% = low speed –100% = full speed).
DMX channel 6 –Manual DWN
There is a 3s delay on this channel to reduce risk of accidentally setting a new range
Channel 6 is used to manually move the wire down.
When channel 6 is in use, it runs the motor in down, until the limit switch DWN is reached.
The position is reset and a new TAC RANGE is calculated. The new range is the tacho pulses,
between top position set by channel 5 and bottom position set by channel 6.
The winch should be reset to the top position with channel 5 before the range is set with
channel 6. 10 –100% makes the motor run down, at variable speed.
(10% = low speed –100% = full speed).

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MENU
The menu structure is divided into two different areas for safer motor control.
Control mode
The display shows: DMX CONTROL .
START CHAN 1
Menu navigation mode
Top Line shows MENU NAVIGATE
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: DMX CONTROL
Push the buttons UP & DOWN and hold them for 3 seconds.
Now the top line of the display should show: MENU NAVIGATE
MENU - DMX CONTROL:
Go back to the starting position and activate DMX control
The top line of the display is showing: MENU NAVIGATE
Push the buttons UP & DOWN and hold them for 3 seconds.
Now the top line of the display is showing: DMX CONTROL
Navigate the menu
The top line of the display is showing: MENU NAVIGATE
Push the buttons UP or DOWN to go up and down in the menu choices.
The bottom line of the display is showing: DMX ADDR 1
Adjusting menu parameters
The top line of the display is showing: MENU NAVIGATE
The bottom line of the display is showing: DMX ADDR 1
Push ENT to change the DMX ADDR value.
The top line of the display is showing: EDIT MENU VALUES
The bottom line of the display is showing: DMX ADDR 1
Save changed value
The top line of the display is showing: EDIT MENU VALUES
The bottom line of the display is showing: DMX ADDR 270
Push ENT to change the top line to: SAVING 1-20
Then press and hold ENT
The top line of the display counts up to 20 then shows OK. SAVING OK
The Value is now saved in the memory.

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Adjusting limit switches
Just under the drum there is a small black box. When you take the lid of this box the limits can be
adjusted.
The limits are adjusted by turning the screws.
First loosen the middle screw.
Then the bottom limit is adjusted by turning the screw with a 1 next to it.
The top limit is adjusted by turning the screw with a 2 next to it.
When adjustments are done tighten the middle screw again.
The limits are factory adjusted to stop 10 cm below the winch and have a travel length of 12.5m.
There must always be 2 rounds left on the drum when the winch is as the bottom limit.
Note: Be careful that the top limit is not set in a position where the load can run into the
winch itself, this might damage the winch.

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Adjustable parameters
Range Default
MAN SPEED Speed for manual driving 200 –2500 800
MAN UP/DWN Run the motor manual from the menu MOTOR UP / MOTOR DOWN
DMX ADDR DMX start address 1 –506 1
TAC RANGE Tacho range 1 –50.000 N/A
SPEED MAX Maximum speed 500 –3500 3500
SP MIN UP Minimum speed UP 50 –1000 200
SP MIN DWN Minimum speed DWN 50 –1000 200
E STOP Enable/disable emergency stop ON-OFF OFF
MAN SPEED and MAN UP/DWN is used for manual control of the motor.
Detailed explanation of parameters
MAN SPEED Speed for manual driving. Range 200 –2500
MAN SPEED sets the speed for manual driving the motor.
MAN UP/DWN Manuelly driving the motor.
MAN UP/DWN is used for manual control of the motor.
Pressing the UP button, makes the wire run up, unless the limit switch is activated
Pressing the DOWN button, makes the wire run down, unless the limit switch is activated
The winch will stop if the Emergency Switch is activated
DMX ADDR DMX start address Range 1 - 506
DMX start address defines which DMX address the Winch 50 reacts on.
The Winch 50 uses minimum 6 DMX channels.
TAC RANGE Tacho range Range 1 –50.000
The tacho range is setting the maximum range of the Winch.
SPEED MAX Maximum speed Range 500 –3500
SPEED MAX sets the maximum speed.
If set to 1000, it means the motor run at 1000 RPM when DMX speed is set to full. SPEED
MAX can be used to lower the maximum speed, e.g. while learning the system.
SP MIN UP Minimum speed up. Range 50 –1000
The motor minimum speed, for the up direction.
The motor is allowed to run at different minimum speed for each direction; this is to
differentiate between different mechanical loads for up and down. See SP MIN DWN.
Set this value to a speed where the motor will still run up at full load.
SP MIN DWN Minimum speed down Range 50 - 1000
The motor minimum speed, for the down direction.
The motor is allowed to run at different minimum speed for each direction, this is to
differentiate between different mechanical loads for up and down, see SP MIN UP.
Set this value to a speed where the motor will still run down at full load.
E STOP Enable/disable emergency stop Range ON - OFF
This enables/disables the emergency stop from the software. However to get the full
functionality of the emergency stop a wire has to be plugged in inside the winch. See section
on how to change the wire setting for more details.

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Normal Operation
Temperatures
If the surface temperature of the winch exceeds 90 degrees Celsius there is a risk of damaging the
winch.
Duty cycle
The winch should not be operated at a duty cycle higher than 30% for longer periods of time.
Lifting speeds and weight
The load of the winch impacts the minimum speed it can operate at. At high loads the minimum
speed up must be increased to a point where the winch can still move.
If a lower load is used with high minimum speeds the winch might have problems with finding its
position. Lower the minimum speeds if this is a problem.
The minimum speed can be adjusted from the menu.
Wire fleet
Because of the way the winch rolls up the wire the place where the wire comes out of the winch
changes depending on how much wire has been rolled out. The wire moves 83mm sideways from
the top position to the bottom position during the movement.

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LED Functions
DMX LED
The DMX lamp will be steady green when receiving a DMX signal.
The DMX lamp will flash green if no DMX signal is present.
Error LED
The error LED will light red if there is an error.
Reset error is done by setting DMX channel 4 to 0.
When the Error LED lights red, there will also be an error description in the display.
Errors and error codes:
Winch will not start, display shows nothing.
Check if the winch is connected to mains power.
Check if the fuse in the winch is blown.
Winch will not start, DMX lamp is blinking.
Check DMX signal
The wire is not wound up on the drum correctly.
Manually lower the wire totally off the drum,
while controlling that the wire comes out of the
winch evenly. Afterwards the wire is rolled back
onto the drum.
Reset the top position afterwards.
Display says “Not in Pos”
The winch cannot move to its position, this
usually occurs when the load is high. To solve
this go into the menu and increase the Minimum
speed up.
Power failure:
The winch will stop at power failure. When the power is re-established, the winch has to be reset
before it is ready to use.
It is advisable to set all the DMX channels on 0 % before the power is re-established.

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Inspections and Maintenance:
Interval of inspections should be determined according to the frequency of use and the working
scenario of the winch.
Signs of malfunction or poor operation should always lead to an inspection of the winch, and the
winch should be taken out of operation until the error is eliminated.
Maintenance plan:
Before every use and Weekly:
Every time when rigging the winch, before running the winch –and at least every week when the
winch is in use:
Check the entire length of the wire rope for bends, crushed areas, broken or cut cord,
corrosion and other damages.
Check all limit switches.
Check the slack detection device
Check the emergency stop.
Check that the wires are winded neatly in the grooves of the drums.
Monthly:
At regular intervals –but at least every month when the winch is in use:
Check the mounting clamps for damages and proper fastening.
Make sure the load is secured to the wire with approved fastening.
Clean the grid of the ventilator and air outlet.
Change damaged parts.
Every 12 month:
The winch has to be inspected by a specialist every 12 months
Every 48 month:
The winch should be inspected by an authorised expert every 48 months.
The results of the regular inspections are to be documented and kept available at the company.
The written result of the last inspection must be kept available at the site of operation, e.g. by an
inspection sticker on the winch showing the date of the inspection, the basis of the inspection and
the name of the inspector.

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Cheat sheet-Winch 50
Before use
When using the Winch 50, always have a counter weight placed in the
wire loop. (Minimum 5 kg)
When using the Winch 50, make sure you can see it, so you have visual
confirmation on the movements.
The Winch 50 uses 6 DMX channels, in order to make it easier to learn how to use it.
Patch out the 6 DMX channels to faders on your lighting desk.
DMX channels
DMX channel 1 –Position. (16 bit DMX channel)
DMX channel 2 –Position fine. (16 bit DMX channel)
DMX channel 3 –Maximum speed
DMX channel 4 –Motor Enable –between 50 % and 55 %, to enable the motor output.
DMX channel 5 –Reset UP
DMX channel 6 –Manual DWN (Set range)
Getting started
1. Hang up the winch, so there is space for the wire to move without hitting the floor.
2. Put counterweight on the wire loop, minimum 5kg.
3. Connect to 230VAC –The display is now showing the start-up message.
4. Set DMX channel 4 between 50 % and 55 %. - Motor is now enabled.
5. Set DMX channel 5 to 50% wait for the load to move to the top position. (There is a 3s
delay on this channel)
When it is at the top position set channel 5 to 0%
6. Set DMX channel 6 to 50 % wait for the wire loop to go 2m down (There is a 3s delay on
this channel)
When the hook is 2m out, set DMX channel 6 back to 0 % - Now the travel range is
from the winch chassis and 2m down.
7. Set DMX channel 1 to 100 % and DMX channel 3 to 20 % - The wire loop is now running
to the top with 20 % speed.
8. Set DMX channel 1 to 50% and DMX channel 3 to 50 % - The wire loop is now running
1m down with 50 % speed.
Emergency stop switch (Only in versions with emergency stop!)
The emergency stop switch is connected to the female 4 pin XLR connector.
Pin 1 and Pin 2 should be connected to each other; otherwise the motor will not run.
Pin out:
Pin 1 = GND Emergency stop input
Pin 2 = NC
Pin 3 = NC
Pin 4 = 12 –15 volt DC Emergency stop input
Jaegergårdsgade 152/05A
DK-8000 Aarhus C
DENMARK
WWW.WAHLBERG.DK