Wahlberg 50 Series User manual

WWW.WAHLBERG.DK JENS JUULS VEJ 1
TELEPHONE: [phone] VIBY
EMAIL: [e-mail] DENMARK
Winch 50 Series
Item No. 245, 246.701 and 246.704
User Manual
Winch 50 Winch 50 Double Winch 50 Double
No. (245) No. (246.701) +Power & Cat5
No. (246.704)

245.805.011 2 Date: 2021-12-09
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 Motion Design 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 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.

245.805.011 3 Date: 2021-12-09
SAFETY INFORMATION 2
INDEX 3
TECHNICAL SPECIFICATIONS 4
DRAWINGS 5
INTRODUCTION 8
PACKAGE CONTENT ...................................................................................................................................... 8
DESCRIPTION............................................................................................................................................... 8
SAFETY FUNCTIONS ...................................................................................................................................... 9
AREA OF USE ............................................................................................................................................... 9
USING FOR THE FIRST TIME ............................................................................................................................ 9
TRANSPORT .............................................................................................................................................. 10
PHYSICAL INSTALLATION 11
FASTENING THE PRODUCT TO A FLAT SURFACE................................................................................................. 11
MOUNTING THE PRODUCT ON A TRUSS .......................................................................................................... 11
MOUNTING THE LOAD ................................................................................................................................ 12
AC POWER 13
POWER CABLES AND POWER PLUG ................................................................................................................ 13
INSTALLING A POWER INPUT OR OUTPUT CONNECTOR ON A POWER CABLE ........................................................... 13
DATA LINK 15
TIPS FOR RELIABLE DATA TRANSMISSION ........................................................................................................ 15
CONNECTING THE DATA LINK ........................................................................................................................ 15
EMERGENCY STOP SWITCH (OPTIONAL) 16
ENABLE EMERGENCY STOP .......................................................................................................................... 17
LIFTING WIRE POWER & ETHERNET (ONLY MODEL 246.704) 17
LIFTING CABLE CONNECTION PLUG ................................................................................................................ 17
CONNECTING THE POWER WIRE .................................................................................................................... 17
SETUP 18
MENU SETTING .......................................................................................................................................... 18
MENU STRUCTURE ..................................................................................................................................... 19
ADJUSTABLE PARAMETERS ........................................................................................................................... 21
DETAILED EXPLANATION OF PARAMETERS ....................................................................................................... 22
DMX ADDRESS SETTING ........................................................................................................................... 24
UNDERSTANDING THE HARD AND SOFT LIMITS ................................................................................................ 25
NORMAL OPERATION ................................................................................................................................. 28
SYNCHRONIZED MOVEMENTS OF MULTIPLE WINCH 50 SERIES ........................................................................... 29
ERROR AND ERROR CODES: .......................................................................................................................... 30
SERVICE AND MAINTENANCE 33
PARTS ...................................................................................................................................................... 33
ON-SITE SERVICE ........................................................................................................................................ 33
MAINTENANCE PLAN .................................................................................................................................. 34
CHECKLIST ................................................................................................................................................ 34
LIFE OF THE WIRE ....................................................................................................................................... 35
WIRE DISCARD CRITERIA .............................................................................................................................. 35
POWERCON TRUE1 .................................................................................................................................. 36
APPENDIX 1 - DIMENSIONS 37
APPENDIX 2 - DIMENSIONS 38
APPENDIX 3 - DIMENSIONS 39
APPENDIX 4 - POWERCON 40
APPENDIX 6 - BLOCK SCHEMATIC 42
WINCH 50 - CHEAT SHEET 44

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Model: Winch 50 Series
Item no.: 245, 246.701 and 246.704
Dimensions (L×W×H):
245 345 × 298 × 464 mm (13.6 × 11.7 × 18.3 in)
246.701 797 × 298 x 464 mm (31.4 × 11.7 x 18.3 in)
246.704 893 x 274 x 455 mm (35.2 x 10.8 x17.9 in)
Power supply: 208-240V/AC 50-60 Hz
Power consumption: 825 W (4,0-3,5A)
Power inlet: Neutrik powerCON TRUE1 NAC3PX-TOP (F/M)
DMX control signal: DMX 512 1990 + DMX512A / 6 channels used
DMX connection: 5 pole XLR (F/M)
Power through connection: (Only model 246.704)
Input: Neutrik powerCON TRUE1 & EtherCON (F)
Output: Neutrik powerCON TRUE1 & EtherCON (M)
Power: 16A/240VAC 2x1.5mm2 (AWG 16)
Signal: Two twisted pairs Cat5 (100 Mbit/s)
Lifting capacity: 50 kg (110.2 lb)
Lifting height: 12,5 m (41 ft)
Lifting speed: 3-84 cm/s (1.2-33.1 in/s)
Minimum load: 3,5kg (7.72 lb)
Noise emission: ~50 dB
Ambient temperature: 5-40°C (32-104°F)
Own weight:
245 29,1 kg (64.2 lb)
246.701 45 kg (99.2 lb)
246.704 52 kg (114.6 lb)
Mounting clamp: 4× Slim eye coupler 42-52 mm (2 in)
Motor: 230V AC, 0.55 kW
Duty cycle: Maximum 30% when running more than 10min.
Lifting wire specifications:
Wire: 3 mm (1/8 in) 19x7 galv. steel wire (EN 12385-4)
Minimum breaking load: 590 kg (5786 N / 1301 lb)
Wire safety factor: >10
Wire angle: None
Wire fleet:
245, 246.701 83 mm (3.3 in)
246.704 80 mm (3.1 in)

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Winch 50 (245)
More detailed drawings and from more angles can be found in Appendix 1 on page 37

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Winch 50 Double (246.701)
More detailed drawings and from more angles can be found in Appendix 2 on page 38

245.805.011 7 Date: 2021-12-09
Winch 50 Double +Power and Cat5 (246.704)
More detailed drawings and from more angles can be found in Appendix 3 on page 39

245.805.011 8 Date: 2021-12-09
Thank you for selecting the Winch 50 Series, a DMX controlled winch 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× Winch 50 / Winch 50 Double / Winch 50 Double +Power and Cat5
1× powerCON NAC3FX-W-TOP female plug for power cable
1× powerCON NAC3FX-W-TOP female plug for power input to bar (246.704 Only)
1x powerCON NAC3MX-W-TOP male plug for power output from bar (246.704 Only)
1× User manual
1× Cheat sheet
Description
Winch 50 Series is a 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 50 kg up
and down. The lifting height is 12.5 m. The lifting speed is between 3 cm/s and 84 cm/s.
The winch is controlled by the standard DMX signal, so a usual lighting desk can be used to control
the movement, programmed as any light.
For a limited 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 50 Series uses 6 channels of the DMX-line, and they control the position, speed, limits,
and reset functions.
The Winch 50 Series has an advanced internal positioning system with 16 Bit, used for finding the
position desired by the operator. With a 16 Bit positioning channel (channel 1 and 2) the operator
can set the desired position, and the winch will run to this position, at the maximum speed applied
on the speed channel (channel 3).
Channel 4 is used as a safety channel. The motor will not run using DMX if channel 4 is not enabled.
With channel 5 and 6 it is possible to set the soft TOP and BOTTOM limits of the movement.
Channel 5 is also used for resetting the winch, when powering up if the position was not saved
when shut down.
On the winch it is also possible to adjust the hard TOP and BOTTOM limits and, in that way, set
the absolute span of motion regardless of any DMX control.
Multiple winches are easily daisy chained with power in-out and DMX in-out, allowing to create
advanced and dynamic movements with several winches working together in the same
installation.

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Safety functions
The control system ensures that the motor only is powered when:
The DMX signal is reliable.
The mode, position and speed control are set correctly.
The drum position is within the span of the soft and hard limits.
No overload.
Winch 50 Series should only be operated by an experienced DMX-controlled-lighting-desk-
operator. The lighting desk must 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 winches by disconnecting
it from the mains. After power failure the start position of the winch may need to be adjusted
before the winch can function properly again.
Manual operation of the winch is only intended for installation, service, and tests.
Area of use
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.
The Winch 50 Series 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 4. Any other use of the
product may result in a risk of injury of persons or equipment damage.
Exceeding the load rating may cause failure of the equipment.
Use only the Wahlberg Motion Design approved mounting connectors to secure the load to the
winch. Failure to mount the load securely can result in a risk of injury of persons or equipment
damage.
Do not modify the product. For any modification contact Wahlberg Motion Design.
It is the customer's sole responsibility to comply with any relevant local laws, regulatory
requirements, and restrictions, concerning the use of the product.
Using for the first time
IMPORTANT! The Winch 50 Series must be protected from environmental factors such as
physical shocks and vibration during transportation and storage.
WARNING 2 before installing, powering, operating, or
servicing the Winch 50 Series. Before applying power to the product.
Check the Wahlberg Motion Design website at www.wahlberg.dk for the most recent
documentation and technical information about the product. Wahlberg Motion Design user
manual revisions are identified by the revision number in the bottom of each page.
2.
Check that the local AC mains power source is within the power voltage and frequency ranges.
page 13. Install the provided Neutrik powerCON TRUE1
NAC3FX-W-TOP power connector on a suitable power cable. If using the power from a mains
power outlet, install a suitable power plug on the power cable.

245.805.011 10 Date: 2021-12-09
Transport
IMPORTANT! The Winch 50 Series 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, fix the wire with a cable tie or an
elastic cord. If the wire is slack it may jump off the drum during transport and cause damage to
the winch.
Use only the original packaging or flight case for protecting the product during transport. Contact
Wahlberg Motion Design for enquiries regarding flight cases or pallet frames.

245.805.011 11 Date: 2021-12-09
WARNING! The Winch 50 Series 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 product if it is not securely fastened.
WARNING! The supporting surface must be hard and flat. Fasten the product securely.
WARNING! Use only the supplied rigging clamps.
WARNING! Make sure the wire exit point is straight downwards in order to maintain the
expected lifetime of the wire.
Fastening the product to a flat surface
The Winch 50 Series 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.
Mounting the product on a truss
The Winch 50 Series can be clamped to a truss or similar rigging structure.
To clamp a product to a truss:
1. Check that the rigging clamps are 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. Block access under the work area. Working from a stable platform, hang the product on the
truss with the mounting clamp upwards. Tighten the rigging clamp.
3. Use the supplied 2 slim couplers sitting on the top plate. It is important to use both slim
couplers for mounting because the load is not evenly distributed across the product.
4. Install a suitable safety cables when the product is hanging over-head and verify that it
complies with either EN 60598-2-17:2018 section 17.7.4 or BGV C1/DGUV 17.
Safety Cable

245.805.011 12 Date: 2021-12-09
Mounting the load
ATTENTION! The load must be mounted on the wire in a way to secure that the load never can
run into the winch.
The load can be mounted using a suitable loading hook designed for lifting. Ensure that the loading
hook has a minimum breaking load of at least 500 kg.

245.805.011 13 Date: 2021-12-09
WARNING 2 before connecting the product to AC mains
power.
WARNING! For protection from electric shock, the product 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 product with power
must be located near the equipment and easily accessible so that the product can easily be
disconnected from power.
WARNING! Check that the voltage range specified on the serial number label matches the local
AC mains power voltage before applying power to the product. Do not apply AC mains power
to the product at any other voltage than that specified.
Power cables and power plug
The Winch 50 Series requires a power input cable with a Neutrik powerCON TRUE1 NAC3FX-W(-
TOP) cable connector for AC mains power input. The cable must rated 20A minimum, have three
conductors 1,5mm2 (AWG 16) minimum conductor size and an outer cable diameter of 6-16mm
(0.24-0.47 inch). Cables must be 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 fo
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
Installing a power input or output connector on a power cable
To install a Neutrik powerCON TRUE1 NAC3FX-W(-TOP)/NAC3MX-W(-TOP) input/output
connector on a power cable, follow the original Neutrik instructions in the Appendix 4 on page 40.

245.805.011 14 Date: 2021-12-09
By supplying power to the winch, the display will show a start-up screen sequence showing the
product name
Followed by a screen showing the software version, e.g. SW 503.002.012 as shown below
Then a description of how to enter the menu
Before it is ready to be controlled by DMX channel 4 should be re-enabled. After it has been re-
enabled it is ready to be operated and shows the following:

245.805.011 15 Date: 2021-12-09
A DMX 512 data link is required in order to control the Winch 50 Series via DMX. The winch has 5-
pin XLR connectors for DMX data input and output. The pin-out on all connectors is pin 1 = shield,
pin 2 = (-), and pin 3 = (+).
Pins 4 and 5 in the 5-pin XLR connectors are not used in normal operation and are available for
possible additional data signals as required by the DMX512-A standard. However, if desired this
additional port may also be used to feedback the actual position of the winch, but in such case, it
is not suitable for daisy chaining.
The Winch 50 Series is subject to the common limit of 32 devices per daisy-chained link. Note that
if independent control of a Winch 50 Series is required, it must have its own DMX channels
assigned. Products that are required to behave identically can share the same DMX channels. To
add more products 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 winch. The
termination plug, which is a male XLR plug with a 120 Ohm, 0.25W resistor soldered between pins
used, terminate each branch of the link.
Connecting the data link
To connect the Winch 50 Series to data:
1. Connect the DMX data output from the DMX controller to the male 5-pin XLR DMX input
connector (DMX 512 IN).
2. Connect the DMX output of the products to the DMX input of another product and
continue connecting products output to input (DMX 512 OUT).
3. Terminate the last product on the link with a 120 Ohm resistor.
The DMX lamp is the green LED, above the display.
Glows constantly, when the DMX connection is correct.
Flashes if the DMX signal is missing or wrongly connected.

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WARNING! By default, the emergency stop is NOT enabled!
The Winch 50 Series 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 winch in operation to 0%. Normally lighting desks
sets all intensity channels to 0% and this will also cause the winch to stop when assigned correctly.
If the emergency stop switch is activated the red Error LED will be lit and the screen display shows:
and the current start channel of the unit:
The emergency stop switch is connected to the male 4 pole XLR connector on the winch. Pin 1 and
Pin 4 should be powered with 12-15 Volt DC to enable operation of the winch.
Pin out: Connection
Pin 1 GND
Pin 2 Not connected
Pin 3 Not connected
Pin 4 12-15 V DC
The emergency stop power supply and plug is available for purchase from Wahlberg Motion
Design.

245.805.011 17 Date: 2021-12-09
Enable Emergency stop
In
to ON
Refer to section
Menu setting on page 18 for guidance on how to navigate the menu.
Ready to use
When the emergency stop has been enabled, and the winch is connected to power, DMX, and an
emergency stop switch, it is ready for use, and can be controlled from the lighting desk.
ing 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.
Warning! Check that the voltage range specified for the lifting wire matches the attached
power voltage before applying power to the lifting wire. Do not apply power to the lifting wire
at any other voltage than that specified in this manual.
Lifting cable connection plug
The Winch 50 Double +Power and EtherCON requires a power input through a Neutrik
powerCON NAC3FX-W-TOP cable connector. The cable for connecting the plug on the winch for
on page 2.
Connecting the power wire
lation of the power connection.
To install a Neutrik powerCON TRUE1 cable connector, follow the original Neutrik instructions
in Appendix 4 on page 40.

245.805.011 18 Date: 2021-12-09
WARNING! Rea 2 before installing, powering, operating, or
servicing the product.
Warning! Before running the winch, it is important to put a counterbalance on the wire. This is
necessary, as the slack detection switch otherwise will be activated and will stop the winch.
WARNING! Only experienced DMX users should operate the product. Contact Wahlberg Motion
Design for further information and education on DMX protocol.
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 1 second to enter and leave the menu navigation
mode, see page 20 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
The display shows:
Shift to next screen by pressing and holding down:
The screen shows the tachometer value for the current position, wanted position, distance and
speed in motor revolutions per minute (RPM).
E.g. the motor is moving with 3000 RPM from current position with tachometer value 10.000 and
the wanted position has the tachometer value of 24.250:
Shift to next screen press and hold.
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:
To shift back to the previous press and hold.
P:
Current position
W:
Wanted
position
D:
Distance from current to wanted position
S:
Speed (values from 0
-
maximum motor
RPM setting in operation)
DMX
channel
1
DMX
channel
2
DMX
channel
3
DMX
channel
4
DMX
channel
5
DMX
channel
6
DMX
channel
7 (not
used)
DMX
channel
8 (not
used)

245.805.011 20 Date: 2021-12-09
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 MANUAL RUN - GOING UP/GOING DOWN 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:
Press to change the DMX ADDRESS value.
The display shows:
Use the arrows or to adjust the DMX ADDRESS.