Wahlberg Winch 25 User manual

WWW.WAHLBERG.DK JENS JUULS VEJ 1
TELEPHONE: [phone] VIBY
EMAIL: [email protected] DENMARK
Winch 25
&
Winch 25 Double
Item No 220 & 221
User Manual
Winch 25 (220) Winch 25 Double (221)

220.805.011 2 Date: 2021-12-09
Safety Information
The following symbols are used to identify important safety information on the product
an in this manual:
This product is for professional use only. It is not for household use.
This product presents risks for severe injury or death due to fire hazards, electric
shock, and falls.
Read this manual before installing, powering or servicing the winch; follow the safety
precautions listed below and observe all warnings in this manual and printed on the
winch. If you have questions about how to operate the winch safely, please contact
you Wahlberg Motion Design supplier or Wahlberg Motion Design.
PROTECTION FROM ELECTRIC SHOCK
−Disconnect the winch from AC power before removing or installing any cover or
part and not when in use.
−Always ground (earth) the winch electrically.
−Use only a source of AC power that complies with local building and electrical
codes and has both overload and ground-fault (earth-fault) protection.
−Before using the winch, check that all power distribution equipment and cables
are in perfect condition and rated for the current requirements of all
connected devices.
−Power input throughput cables must be rated 20 A minimum, have three
conductors 1.5 mm2(AWG16) minimum conductor size and an outer cable
diameter of 5-15 mm (0.2-0.6 inch). Cables must be hard usage type (SJT or
equivalent) and heat-resistant to 90°C (194°F) minimum. In the EU the cables
must be <HAR> or equivalent.
−Use only Neutrik powerCON TRUE1 NAC3FX-W cable connectors to connect to
power input sockets.
−Assembly power supply cables following the instructions in this manual only
(see page 15).
−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

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−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 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 Motion Design 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 12.
−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
on page 12.
−If possible, allow enough clearance beneath the winch so it cannot cause any
danger to personnel beneath it. Alternatively, 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.
−Do not use the winch over the head of people
−Do not use the winch to lift people or animals.
−Only use the winch to lift static loads.
Inspection
points
Intact wire
Broken wire
Before each use
−Check that the winch is safely and correctly installed/mounted.
−Inspect the entire length of the wire for bends, damage and
wear, cut cords, corrosion and abuse.
−Inspect the wire ferrule crimp and thimble for damage, wear,
corrosion or abuse.
−Check the load is safely mounted and weighs max. 25 kg (55.1 lb).
−Check safety functions (limit switches, slack detection,
emergency stop)
−Check that the wire is wound neatly on the drum
Warning! Do not use the winch if any damage or error is found!

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Disposing of this product
Wahlberg Motion Design products are supplied in compliance with Directive
2002/96/EC of the European Parliament and of the Council of the European
Union on WEEE (Waste Electrical and Electronic Equipment), as amended
by Directive 2003/108/EC, where applicable.
Help preserve the environment! Ensure that this product is recycled at the
end of its life. Your supplier can give details of local arrangements for the
disposal of Wahlberg Motion Design products.

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Index
SAFETY INFORMATION 2
INDEX 3
TECHNICAL SPECIFICATIONS 6
DRAWING 7
PACKAGE CONTENT ......................................................................................... 9
DESCRIPTION................................................................................................ 9
SAFETY FUNCTIONS ........................................................................................10
AREA OF USE...............................................................................................10
USING FOR THE FIRST TIME .................................................................................10
TRANSPORT................................................................................................11
PHYSICAL INSTALLATION 12
FASTENING THE WINCH TO A FLAT SURFACE ................................................................12
MOUNTING THE WINCH ON A TRUSS ........................................................................12
AC POWER 14
POWER CABLES AND POWER PLUG ..........................................................................14
INSTALLING A POWER INPUT CONNECTOR ON A POWER CABLE ...............................................15
DATA LINK 16
TIPS FOR RELIABLE DATA TRANSMISSION ....................................................................16
CONNECTING THE DMX ....................................................................................16
EMERGENCY STOP SWITCH (OPTIONAL) 17
ENABLE EMERGENCY STOP .................................................................................18
READY TO USE .............................................................................................18
LIFTING WIRE POWER (ONLY MODEL 221) 19
LIFTING CABLE CONNECTION PLUG .........................................................................19
CONNECTING THE POWER WIRE.............................................................................19
SET UP 20
COUNTERBALANCE .........................................................................................20
MENU SETTING.............................................................................................20
MENU STRUCTURE..........................................................................................21
ADJUSTABLE PARAMETERS..................................................................................23
DETAILED EXPLANATION OF PARAMETERS ...................................................................24
DMX ADDRESS SETTING ..................................................................................26
ADJUSTING HARD LIMIT SWITCHES ..........................................................................27
NORMAL OPERATION .......................................................................................29
SYNCHRONIZED MOVEMENTS OF MULTIPLE WINCHES.........................................................30
LED FUNCTIONS ...........................................................................................31
ERROR AND ERROR CODES: .................................................................................31
SERVICE AND MAINTENANCE 34
PARTS .....................................................................................................34
ON-SITE SERVICE...........................................................................................34
MAINTENANCE PLAN........................................................................................35
CHECKLIST .................................................................................................35
LIFE OF THE WIRE ..........................................................................................36
WIRE DISCARD CRITERIA ....................................................................................36
APPENDIX 1 38
APPENDIX 2 39
APPENDIX 3 40
APPENDIX 4 42
APPENDIX 5 43
WINCH 25 - CHEAT SHEET 44

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Technical specifications
Model: Winch 25
Item no.: 220
Dimensions (L×W×H):
220 287 × 229 × 355 mm (11.3 × 9.01 × 14.0 in)
221 687 × 229 × 355 mm (27.0 × 9.01 × 14.0 in)
Power supply: 200-240V AC 50-60 Hz
Power consumption: 300 Watt
Power inlet: Neutrik powerCON TRUE1 NAC3PX (F/M)
DMX control signal: DMX 512 1990 + DMX512A / 6 channels used
DMX connection: 5 pole XLR, male & female
Lifting height: 10 m (33 ft.)
Lifting capacity: 25 kg (55 lb)
Lifting speed: Variable, 3-60 cm/s (1.2-23.6 in/s)
Minimum load: 1.0 kg (2.2 lb)
Noise emission: ~50 dB
Ambient temperature: 0-40°C (32-104°F)
Own weight:
220 21 kg (46.5 lb)
221 32 kg (70.5 lb)
Mounting clamp: 2× Slim eye coupler 50 mm (2 in)
Motor: 230V AC, 0.25 kW 2800 rpm
Duty cycle: Maximum 30% at max. load (refer to page 29)
Minimum 23 min OFF after 10 minutes ON
Lifting wire specifications:
Lifting wire: 2 mm (5/64 in) 7×7 PP coated galv. steel wire
(EN 12385-4)
Minimum breaking load (wire): 280 kg (2.75 kN / 618 lb)
Wire safety factor: minimum 10
Wire fleet: 76 mm (3.0 in)
Wire fleet angle: None

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Drawing
W25 (220)
More detailed drawings and from more angles can be found in Appendix 1 on page 38

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W25 Double (221)
More detailed drawings and from more angles can be found in Appendix 2 on page 39

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Introduction
Thank you for selecting the Winch 25, 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 25 / Winch 25 Double
1× PowerCON NAC3FX-W female plug for power cable
2× SpeakON NL4FX for attachment current (Winch25 Double only)
1× User manual
1× Cheat sheet
Description
Winch 25 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 a maximum load of
25 kg up and down. The lifting height is 10 m. The lifting speed is between 3 cm/s and
60 cm/s.
The winch is controlled by the standard DMX controlling signal, so a normal lighting
desk can be used to control the movement, programmed as normal light.
For a low number of winches, a standard lighting desk can be used, but when many
winches are used, more advanced desks should be used to maintain easy control of the
units.
The Winch 25 uses 6 channels of the DMX-line, and they control the position, speed,
limits, and reset functions.
The Roll Down 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 MSB
and channel 2 LSB) the operator can set the desired position, and the Roll Down will
run to this position, at the maximum speed (channel 3).
Channel 4 is used to enable power.
With channel 5 and 6 it is possible to set the soft TOP and BOTTOM limits of the
movement of the winch, adjusting its span of motion. Channel 5 is likewise used for
resetting the winch, when powering up.
On the winch it is possible to adjust the hard TOP and BOTTOM limits and in that way
set the absolute span of motion.
Multiple winches are easily daisy chained with power in-out and DMX in-Out, allowing
to create advanced and dynamic movements with 100’s of winches working together in
the same installation.

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Safety functions
The control system ensures that the motor only is powered when:
•The control signal is reliable.
•The position and speed control is on.
•The drum position is within the span of the soft and hard limits.
•No overload.
Winch 25 should only be operated by an experienced DMX-controlled-lighting-desk-
operator. The lighting desk has to be programmed according to the manual, so the
winch will stop when the speed is put to 0 %. It is also possible for the user to stop the
winch by disconnecting it from the mains power. After power failure the soft TOP
position of the winch needs to be reset before the winch can function again.
Manual operation of the winch is only intended for mounting, service, and tests.
Area of use
For indoor use only!
Caution! To reduce the risk of electric shock or injury: use indoors only
Caution! To reduce the risk of electric shock, do not expose to rain: store indoors!
The Winch is intended for indoor use only. It is designed for lifting and lowering
material at the weight and speed stated in "Technical specifications" on page 6. Any
other use of the winch may result in a risk of injury of persons or equipment damage.
Exceeding the load rating may cause failure of the equipment.
Use only approved rigging connectors to secure the load to the wire and do not wrap
the wire around the load as this will damage the wire and result in a risk of injury of
persons or equipment damage.
Do not modify the winch. For any modification of your winch, contact Wahlberg 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 winch.
Using for the first time
Important! The Winch 25 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 25. Wahlberg Motion
Design user manual revisions are identified by the revision number in the bottom of
each page.
−Carefully review the “Safety Instructions” on page 2.
−Check that the local AC mains power source is within the winch power voltage and
frequency ranges.
−See “Power cables and power plug” on page 2. Install a Neutrik powerCON TRUE1
NAC3FX-W power input connector on a suitable power cable. If using the power from
a mains power outlet, install a suitable power plug on the power cable.

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Transport
Important! The Winch 25 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 loose it may jump off the wire wheel during
transport and cause damage to the winch.
Use only the original packaging, flight case, or pallet frame for protecting the winch
during transport. Contact Wahlberg Motion Design for enquiries regarding flight cases
or pallet frames.

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Physical installation
Warning! The Winch 25 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 25 if it is not securely fastened.
Warning! The supporting surface must be hard and flat. Fasten the winch securely.
Warning! Use only the supplied rigging clamps.
Fastening the winch to a flat surface
The Winch 25 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.
Mounting the winch on a truss
The Winch 25 can be clamped to a truss or similar rigging structure.
To clamp a Winch 25 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 winches and equipment to
be installed on it.
2. 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.
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 winch.

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Mounting the load
Attention! The load must be mounted on the wire in a way to insure that the load
never can run into the winch.
The load can be mounted using the supplied loading hook or any other hooks designed
for lifting. Ensure that the loading hook has a minimum breaking load of at least 250
kg.

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AC power
Warning! Read “Safety Information” on page 2 before connecting the Winch 25 to
AC mains power.
Warning! For protection from electric shock, the Winch 25 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 25
with power must be located near the winch and easily accessible so that the winch
can easily be disconnected from power.
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 25 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.

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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 as described in Appendix 3 in page 40.
By supplying power to the winch, the display will show a start-up screen sequence
showing the model number
Followed by a screen showing the software version, e.g. SW 503.003.012 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:

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Data link
A DMX 512 data link is required in order to control the winch via DMX. The Winch 25
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 the Winch 25 but are available for possible additional data signals as
required by the DMX512-A standard.
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 25 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. 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, 0.25 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 DMX
To connect the Winch 25 to data:
1. Connect the DMX data output from the DMX controller to the Winch 25’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 winch 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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Emergency stop switch (Optional)
Warning! By default the emergency stop is NOT enabled!
The Winch 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 have a
“blackout” button that sets all signals to 0% and this will also cause the winch to stop.
If the emergency stop switch is activated the red Error LED will be lit and the screen
display shows: ‘EMERGENCY STOP PRESSED’ 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 DV
The emergency stop power supply and plug is available for purchase from Wahlberg Motion
Design.

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Enable Emergency stop
In ‘MENU NAVIGATE’ change ‘E STOP’ from OFF
to ON
Refer to section Menu setting on page 20 for guidance on how to navigate the menu.
Ready to use
When the emergency stop has been enabled both in the menu and in the winch, the
Winch 25 connected to power, DMX, and an emergency stop switch, it is ready for use,
and can be controlled from the lighting desk.
Please check that the emergency stop is working under safe conditions before it
becomes necessary. Check this by running the winch and unplugging the emergency
stop. This should stop the winch safely and the red Error LED will be lit.

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Lifting wire power (Only model 221)
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.
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 25 double requires a power input through a Neutrik speakON NL4FX cable
connector. The cable for connecting the speakON plug on the winch for the lifting wire
power, must meet the requirements listed under “Protection from electric shock” on
page 2.
The winches two lifting wires are used as conductors for power up to 48 V.
Connecting the power wire
Refer to the section “AC power” on page 14 for installation of the power connection.
To install a Neutrik speakON NL4FX cable connector, follow the original Neutrik
instructions in Appendix 4.

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Set up
Warning! Read “Safety Information” on page 2before installing, powering,
operating, or servicing the Winch 25.
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 winch. Contact Wahlberg
Motion Design for further information and education on DMX protocol.
Counterbalance
When the winch has been mounted, it is important to hook on a counterbalance before
running with it. This can be done by hanging some sort of load at the end of the wire.
The counterbalance is very important, because the winch will not run without it.
Menu setting
Use the push buttons on the display to enter and change menu settings
Use the arrows & to go up or down in the menu
Push to set values.
Push to go back one level in the menu