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Summary of Contents for Wahlberg Winch 25
- Page 1 Winch 25 & Winch 25 Double Item No 220 & 221 User Manual Winch 25 (220) Winch 25 Double (221) WWW.WAHLBERG.DK JENS JUULS VEJ 1 TELEPHONE: +45 86 18 14 20 8260 VIBY EMAIL: sales@wahlberg.dk DENMARK...
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Page 2: Safety Information
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 −... -
Page 3: Before Each Use
− 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. -
Page 4: Disposing Of This Product
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. - Page 5 ................... 34 SITE SERVICE ..................35 AINTENANCE PLAN ....................35 HECKLIST ..................36 IFE OF THE WIRE ..................36 IRE DISCARD CRITERIA APPENDIX 1 APPENDIX 2 APPENDIX 3 APPENDIX 4 APPENDIX 5 WINCH 25 - CHEAT SHEET 220.805.011 Date: 2021-12-09...
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Page 6: Technical Specifications
Technical specifications Model: Winch 25 Item no.: Dimensions (L×W×H): 287 × 229 × 355 mm (11.3 × 9.01 × 14.0 in) 687 × 229 × 355 mm (27.0 × 9.01 × 14.0 in) Power supply: 200-240V AC 50-60 Hz Power consumption:... - Page 7 Drawing W25 (220) More detailed drawings and from more angles can be found in Appendix 1 on page 38 220.805.011 Date: 2021-12-09...
- Page 8 W25 Double (221) More detailed drawings and from more angles can be found in Appendix 2 on page 39 220.805.011 Date: 2021-12-09...
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Page 9: Package Content
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. -
Page 10: Safety Functions
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. - Page 11 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.
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Page 12: Physical Installation
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. - Page 13 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.
- Page 14 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.
- Page 15 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.
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Page 16: Tips For Reliable Data Transmission
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. - Page 17 Pin 1 and Pin 4 should be powered with 12-15 volt DC to enable operation of the winch. Pin out: Connection Pin 1 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. 220.805.011 Date: 2021-12-09...
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Page 18: 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. - Page 19 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”...
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Page 20: Menu Setting
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. -
Page 21: Menu Structure
Menu structure The menu structure is divided into two different areas for safer motor control. Control mode and menu navigation mode. To change between the two push both buttons & and hold them for 3 seconds. Control mode The display shows: Shift to next screen by pushing and hold for 3 seconds: Current position (values from 0-99.999) - Page 22 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 to go up or down in the menu choices.
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Page 23: Adjustable Parameters
Save changed value The display shows: Push to change the top line to: Where X is an increasing number from 1 to 20. Then push and hold . The top line of the display counts up to 20 then shows OK. The value is now saved in the memory. -
Page 24: Detailed Explanation Of Parameters
DMX ADDRESS DMX start address Range 1-506 DMX start address defines which DMX address the Winch 25 reacts on. TAC RANGE Tacho range Range 1-99,999 The tacho range is setting the range of the winch from the soft TOP limit to the soft BOTTOM limit. - Page 25 Shows how many hours the winch has been powered on Since Last Service reset (SLS RESET). SLS RESET Reset Since Last Service parameters NO/YES Set all SLS values to zero. Go through all service steps described in the manual and contact Wahlberg Motion Design for any spare parts. TOT DIST Kilometres moved in total Shows how many kilometres the winch has travelled since production.
- Page 26 DMX ADDRESS setting The DMX address, also known as the start channel, is the first channel used to receive instructions from the controller. For independent control, each product must be assigned to its own control channels. The DMX address is configured in the menu as described in the section above.
- Page 27 Adjusting hard limit switches Warning! There must be at least 2 rounds left on the drum when the winch is at the hard BOTTOM limit. Attention! Be careful that the hard TOP limit is not set in a position where the load can run into the winch itself, this will damage the winch.
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Page 28: Adjusting Procedure
Adjusting procedure 1. Put the winch in manual mode while adjusting the limits. 2. Localise the hard limit switch box, the black box just beneath the drum. 3. Loosen the two screws holding the lid. 4. Loosen the middle screw. 5. -
Page 29: Duty Cycle
Normal Operation Temperatures If the surface temperature of the winch exceeds 90°C (194°F) 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. - Page 30 Synchronized movements of multiple winches If several winches are installed to perform synchronized movements, the best result is achieved by using a fading 16 bit position. The winches have a slight deviation in performance of the motors, so some motors have a slightly higher maximum speed than others.
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Page 31: Led Functions
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. - Page 32 Code Error message Cause Solution UNDERVOLTAGE Shutdown due to undervoltage in the DC The input voltage might be too low. link. OVERVOLTAGE Shutdown due to overvoltage in the DC link. The input voltage might be too high. OVERTEMP. >70C Shut down due to inverter overheat. The temperature of the power electronics in the frequency inverter is too high.
- Page 33 INV NOT ENABLED Inverter enable signal missing at the control The inverter can only be started if an active enabling signal (12-15 V) is applied terminal rail, terminal 3. to the control terminal rail. If this signal fails during drive operations, the motor will shut down and coast to a standstill.
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Page 34: Service And Maintenance
Parts Only parts ordered at or approved by Wahlberg Motion Design should be used in the winch to ensure product function and stability. Contact Wahlberg Motion Design to inquire about spare parts. -
Page 35: Maintenance Plan
Maintenance plan The results of all 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. - Page 36 Life of the wire It is Wahlberg Motion Design policy to apply the strictest possible calibration procedures and use the best quality materials available to ensure optimum performance and the longest possible component lifetimes. However, wires are subject to wear and tear over the life of the product, resulting in special attention to the state of the wire.
- Page 37 − When the core of the wire has collapsed. − When the wire has been subjected to a high temperature or heat due to fire. − When the wire has been subjected to severe shock load or over load due to an accident with the winch.
- Page 38 Appendix 1 Winch 25 (220) 220.805.011 Date: 2021-12-09...
- Page 39 Appendix 2 Winch 25 Double (221) 220.805.011 Date: 2021-12-09...
- Page 40 Appendix 3 220.805.011 Date: 2021-12-09...
- Page 41 220.805.011 Date: 2021-12-09...
- Page 42 Appendix 4 220.805.011 Date: 2021-12-09...
- Page 43 Appendix 5 Block diagram of the control system of the winch. 220.805.011 Date: 2021-12-09...
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Page 44: How To Get Started
Winch 25 - Cheat Sheet DMX channels Function Position rough (Hi of a 16 bit DMX channel) Position fine (Lo of a 16 bit DMX channel) Set the maximum speed Motor Enable – between 50% and 55% to enable the motor output...
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