Wahlberg Winch 25 User manual

805.221.002 Date: October 14, 2016
Winch25 Double - appendix
Slackdetection
The Winch 25 is supplied with a mechanical slackwire-detection for each wire. This function is
only used as safety-precaution, wireslack should always be avoided in normal operation.
If the slackdetection is activated (no pull on the wire), the winch will not operate - neither up nor
down.
Slack detection switches
Rotary limit switch

805.221.002 Date: October 14, 2016
Rotary limit switches:
The rotary limit switches is functioning as a working area limit switches.
The TOP-limit switch has a factory setting - at ~10 cm under the winch.
The BUTTON - limit switch has a factory setting - at 10 meter under the winch.
The BUTTON limit switch can be adjusted to another setting, up to 15 meter, but the working area
can also be adjusted from the DMX control -
Adjusting the limit-switches:
Loosen the center screw.
Adjust appropriate switch-cam by turning its set-screw.
Top-limit is the upper cam - adjusted by screw nr: 2
Bottom-limit is the lower cam - adjusted by screw nr: 1
After setting - tighten the center screw again.
Center screw
Bottom-limit - screw nr: 1
Top-limit - screw nr: 2

805.221.002 Date: October 14, 2016
Lifting Wire.
The nylon-coated wires carry live main voltage for the power for the chandelier lamp.
Inspect wires daily for wear or damages on the nylon insulation.
Wire and "Slack detection rolls should be greased with a thin layer of silicone-grease.
This grease helps the wire rolling on the drums and prevents the wire from slipping sideways.
if the wire gets dried out, re-apply a thin layer of grease.
Caution -- The exposed wire will have power applied to the object mounted on the winch.

805.221.002 Date: October 14, 2016

805.221.002 Date: October 14, 2016
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 limit –top –Manual UP
DMX channel 6 –Reset limit bottom - Manual DWN, (Sets the TAC RANGE)
Getting started
Hang the winch, so there is space for the wire to move without hitting the floor.
Put counterweight on the wire loop, minimum 1kg.
Connect to 230VAC –The display is now showing the start-up message.
Connect emergency switch if emergency switch is active. - Make sure the error LED is no
longer red.
Setting the working range
Hang the winch, so there is space for the wire to move without hitting the floor.
Put counterweight on the wire loop, minimum 1kg.
Connect to 230VAC –The display is now showing the start-up message.
Connect emergency switch. - Make sure the error LED is no longer red.
Set ALL CHAN 1, 2, 3, 4, 5, 6 to 0%.
Set CHAN 4 between 50 % and 55 %. Motor is now enabled.
1: Setting the top –limit.
Set CHAN 5 at 20% The winch is now moving up, with 20% speed after being
active for more than ~3s.
Wait until the “BAR” is at the top position (motor stops)
Set CHAN 5 at 0% The winch is now stopped at the top point, and the top-
position is found.
2: Setting the Bottom –limit.
Set CHAN 6 at 20% The winch is now moving DOWN, with 20% speed after
being active for more than ~3s.
While running down, look at the winch, and when the winch reaches the point you want to set
as button limit:
Set CHAN 6 at 0% The winch is now stopped at the bottom point, and the
button limit is found.
Now the working range is set (TAC range), and during power down the winch remembers the
working range.
When powering up the winch, you only need to “set the TOP limit” with the use of CHAN 5.
The working range (TAC range) can also be adjusted in the menu of the winch, but the use of
channel 6 is always overriding the setting the menu.

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220 Winch 25
User Manual

805.220.007 Date: January 19, 2017
2
Index:
GENERAL 3
PRODUCT CONTENT 4
DESCRIPTION 4
AREA OF USE 4
WINCH 25 FEATURES 6
CONNECTING THE WINCH 7
ADJUSTING THE LIMIT SWITCHES 8
MENU 11
LIFTING CAPACITY AND REQUIRED SETTINGS FEJL!BOGMÆRKE ER IKKE DEFINERET.
CONTINUOUS USE FEJL!BOGMÆRKE ER IKKE DEFINERET.
LED FUNCTIONS 15
ERRORS AND ERROR CODES: 15
POWER FAILURE 15
INSPECTIONS AND MAINTENANCE 16
MAINTENANCE PLAN 16
ROLLING UP THE WIRE 17
CHEAT SHEET -WINCH 25 18

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TECHNICAL SPECIFICATIONS:
Item No. : 220
Dimensions : 400 x 225 x 290 mm / 15.74 x 8.86 x 11.42 in (Height-Width-Depth)
Power supply : 230 volt AC 50 - 60Hz.
Power consumption : Max 300 Watt.
Power plug : Neutrik powerCON male
DMX Control signal : DMX 512 1990 + DMX 512A / 6 Channels used
DMX connection : 5 pole XLR, In & link
Lifting height : 10 m. (33 ft.)
Lifting capacity : 25 kg. (55 lbs.)
Lifting speed : Variable 5-40cm/s (2-15.7in/s)
Lifting cable : 2mm galvanised steel wire, 8mm snap hook, MBL 281 kg (620 lbs.)
Min. Load : 1 kg. Lower weight can course wire winding problems.
Wire Fleet : 85mm (3.3 in)
Ambient temperature : 0-40 °C (32- 104 °F)
Duty cycle : Max 30% at max load
Noise emission : ~50 dB
Weight : 21 kg. (46 lbs.)
Mounting clamp : Slim eye coupler (Max load: 300 kg)
Two couplers separated by 202mm (7.88 in)
Motor : 230 V AC, 0.25 kW, IP55

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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 25
1 Powercon plug for cable
1 Instruction manual
Description
The Winch25 is a wire winch for lifting and moving scene objects.
The winch is controlled from the lighting desk, and thereby stage movements can be controlled in
corporation with the lights, this will add dynamic to the performance or play.
Winch25 has an advanced positioning system that 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.
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 on the main.
After power failure the start position of the winch should be reset.
The winch is for indoor use only!
Area of use:
The Winch is intended for indoor use. 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. Any modification you might need should be done by Wahlberg.
It is the customers' responsibility that any local restrictions concerning the use of the winch are
complied with.
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."

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Attention!
Before running the winch read the user’s 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 running 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.
During set-up and each time before use, the safe condition of the winch must be established with a
visual inspection and a functionality test.
Pay special attention to the mounting of the winch and the condition of the wire!
Cautions at 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.
Warning!
Use of the winch for other than the intended purpose can cause injury!

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Winch 25 Features
The Winch25 is a wire winch for lifting and moving scene objects.
The winch is controlled from the lighting desk, and thereby stage movements can be controlled in
corporation with the lights, this will add dynamic to the performance or play.
Winch25 has an advanced positioning system that 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 Winch25 is turned on the winch cannot run before DMX channel 4 has been out of the
enable area of 50-55 %, after this the winch has to be reset again.
Counterweight:
It is very important to have at least 1Kg load on the wire before start running the winch. If no
weight is applied in the wire, it will jam on the drum.
DMX channels used for controlling the winch
(For a more detailed description see page 9)
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)
Resetting the up position:
Channel 5 needs to be active for ~3s before the winch will start resetting.
Run the motor to the top reset position, with channel 5.
Setting DMX channel 5 to 0% resets the top position

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Connecting the Winch
Power supply
The Winch 25 must be connected to 208-240VAC,
Power is connected to the blue Neutric Powercon connector.
By supplying power to the winch, the display will show a start-up 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 blink when no
DMX are received.
Ready to use
When the winch has been connected to 230VAC and a DMX light desk it is ready for use, and
can be controlled from the light desk.

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Adjusting the limit switches
To adjust the limits first remove the black cover, it is
attached with two screws.
The limit switch determines the maximum and
minimum travel distance of the winch.
To adjust the limit switch loosen the middle screw.
Then the top and bottom limits can be adjusted with
the two screws. The limits are adjusted by rotating the
white levers using the screws for top and bottom limit.
While adjusting the limits put the winch in manual
mode. The winch will write out LIMIT TOP ACT
when it hits the top limit while moving up and LIMIT
BOTTOM when it hits the bottom limit going down.
When adjusting a click can be heard when the switch
is pressed or released.
When adjustments are done make sure to tighten the
centre screw again!

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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 25 is connected to the power supply and a DMX light-desk it is ready for
use and can be controlled from the light-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 run.
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.
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, (Sets the TAC RANGE)
There is a 3s delay on this channel to reduce risk of accidentally setting a new range
Channel 6 is used to manual move the wire down.
When channel 6 is in use, it runs the motor down, until the limit switch DOWN 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.
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
Control mode –Expanded view
Expanded view is activated by holding the DOWN button for approx. 5 seconds.
Here it is possible to watch the different parameters:
P = ACTUAL POSITION D = DELTA POSITION
W = WANTED DMX POSITON S = SPEED
Holding the DOWN button for further 5 seconds will reveal the received DMX values in the
menu. The value is shown in the menu as this:
CH1 CH2 CH3 CH4
CH5 CH6 CH7 CH8
Menu navigation mode
Top Line shows MENU NAVIGATE
In menu navigate mode, the different parameters can be changed, e.g. DMX, address, max speed
etc.
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 & 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

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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
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.
Adjustable parameters Range Default
MAN SPEED Speed for manual driving 200 –1200 500
MAN UP/DOWN Run the motor manual from the menu MOTOR UP / MOTOR DOWN
DMX ADDR DMX start address 1 –506 1
TAC RANGE Tacho range 1 –32000 28900
SPEED MAX Maximum speed 500 –3500 2800
SP MIN UP Minimum speed UP 200 –1000 200
SP MIN DOWN Minimum speed DOWN 100 –1000 200
E STOP Enable/disable emergency stop ON-OFF OFF
MAN SPEED and MAN UP/DOWN are used for manual control of the motor. The motor is only
running as long as the UP or DOWN arrow is pressed.

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Detailed explanation of all parameters
MAN SPEED Speed for manual driving. Range 200 –1200
MAN SPEED sets the speed for manual driving the motor.
1200 sets the maximum speed to 1200 RPM and 200 sets the minimum speed.
MAN UP/DWN Manuel 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.
DMX ADDR DMX start address Range 1 - 509
DMX start address defines which DMX address the Winch 25 reacts on.
TAC RANGE Tacho range Range 0 –32.000
The tacho range is setting the maximum range of the Winch.
The tacho range can be set to higher values by manually running the winch with channel 6.
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 200 –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 100 - 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 light steady green when receiving a DMX signal.
The DMX lamp will blink 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 toggling the 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 winch will not run, DMX LED is steady
green.
Check limit switch inputs are connected.
Check slack detection.
The wire is not wound up on the drum correctly.
Manually lower the wire totally of the drum,
while controlling that the wire comes out of the
winch nicely. Afterwards the wire is rolled back
onto the drum.
Reset the top position afterwards.
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.