Manuals and Technical Documents

• The product is for professional use and presents risks for severe injury or death.
• Always warm up electronic equipment to room temperature before applying power.
• Isolate the product from power immediately if it is defective or shows signs of overload. Do not reapply power until repairs have been completed.
• Do not modify the product in any way not described in the manual.
• Refer any service operation not described in the manual to a qualified technician.
• Install only genuine Wahlberg parts.

• Fasten the product securely to a fixed surface, rig or structure as described in the manual.
• Ensure that any supporting hardware can hold at least 10 times the weight of all the devices it supports.
• 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.
• Only operate the winch when there is a clear view to the winch and the area beneath it.
• Before running the winch, ensure that the area beneath it is cleared to avoid risk of injury.

• 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.
• The winch must be grounded (earthed).

• 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.
• If the surface temperature of the Winch 10 / Winch 3 exceeds 70 °C (194 °F), there is a risk of damaging the winch.

No. The winch is intended for indoor use only. Do not expose it to rain, and store it indoors.

The winch is designed for lifting and lowering material at the weight and speed stated in the technical specifications. Any other use may result in a risk of injury of persons or equipment damage. Exceeding the load rating may cause failure of the equipment. The maximum load is 10 kg (22 lb) for the Winch 10 and 3 kg (6.7 lb) for the Winch 3.

• Use only approved rigging connectors to secure the load to the wire.
• Do not wrap the wire around the load, as this will damage the wire and result in a risk of injury or equipment damage.
• Do not modify the winch. For any modification of your winch, contact Wahlberg.
• It is the customer’s sole responsibility to comply with any relevant local laws, regulatory requirements and restrictions concerning the use of the winch.

The winch should only be operated by an experienced lighting desk operator, and only experienced DMX users should operate it. Contact Wahlberg for further information and education on the DMX protocol.

Protect the winch from physical shocks and vibration during storage. Before applying power:

• Check www.wahlberg.dk for the most recent documentation and technical information about the Winch 10 / Winch 3. Wahlberg user manual revisions are identified by the revision number at the bottom of each page.
• Carefully review the safety instructions in the manual.
• Check that the local AC mains power source is within the winch’s power voltage and frequency range.
• Install a Neutrik powerCON TRUE1 female power input connector on a suitable power cable. If using power from a mains power outlet, install a suitable power plug on the power cable.

• Before transport, roll the wire up to the hard TOP limit so that a maximum of 5 cm (1.9 in) remains out of the winch. If the wire is slack, it may jump off the wire wheel during transport and cause damage to the winch.
• Protect the winch from physical shocks and vibration during transport.
• Use only the original packaging, flight case or pallet frame. Contact Wahlberg for enquiries regarding flight cases or pallet frames.

The winch 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 exits downwards. Do not apply power to the winch if it is not securely fastened. If fastening to a flat surface, the supporting surface must be hard and flat. Check that the surface can support at least 10 times the weight of all winches and equipment installed on it.

Warning: Use only the supplied rigging clamp and M12 bolt. The clamp must be screwed into the central hole in the winch’s mounting bracket using the supplied M12 washers and M12 locking-nut.

1. Check that the rigging clamp is 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. Use the supplied rigging clamp, or contact Wahlberg Motion Design for a replacement.
3. Fasten the clamp to the winch with the supplied M12 bolt, nut and washers in the hole in the mounting clamp of the winch.
4. 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.
5. Install a suitable safety cable through the clamp bracket when hanging overhead.

The manual’s photo on page 9 shows four winches clamped to a truss, with the safety cable marked.

• The load must be mounted on the wire in a way that ensures it can never run into the winch.
• The load can be mounted using the supplied loading hook or any other hooks designed for lifting.
• The loading hook must have a minimum breaking load of at least 100 kg.

Yes. Before running the winch, put a counterbalance on the wire. The winch has a slack detection device that stops the motor from moving down if the wire becomes loose. Without a counterweight attached to the wire hook, the winch will not work properly and will not run further down. The specifications list a minimum load of 0.45 kg (0.99 lb), and the manual’s quick start uses a counterweight of at least 0.45 kg (0.99 lb).

The winch will always run up if directed to do so, except if the TOP limit switch is unintentionally activated before the top position is reached. Slack detection has no influence on the ability to move up.

• A power input cable with a Neutrik powerCON TRUE1 female cable connector for AC mains input.
• A Neutrik powerCON TRUE1 male cable connector for AC through, for daisy chaining.
• The cable must be rated 20 A minimum, have three conductors of 1.5 mm² (AWG 16) minimum conductor size, and an outer cable diameter of 6–16 mm (0.24–0.47 in).
• Cables must be heat resistant to 90 °C (194 °F) minimum.
• In the EU the cables must be approved or equivalent. 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 rated 20 A for USA and 16 A for Europe. Follow the plug manufacturer’s instructions.

If pins are not clearly identified, or if you have any doubts about proper installation, consult a qualified electrician.

• The winch must be grounded (earthed).
• The power distribution circuit must be equipped with a fuse or circuit breaker and ground-fault (earth-fault) protection.
• Socket outlets or external power switches used to supply the winch must be located near the winch and be easily accessible, so the winch can easily be disconnected from power.
• Check that the voltage range selector matches the local AC mains voltage before applying power. Do not apply AC mains power at any other voltage than specified on the winch’s serial number label.

The winch has 4 plugs. At the top are 2 DMX plugs: one for connecting DMX in and one for daisy chaining DMX to other devices. Below are a POWER in plug and a plug for daisy chaining power between multiple devices. Below those plugs are the voltage selector and the fuse (marked MAX 2A). The voltage selector must be set to the appropriate voltage before power is applied to the winch.

• Check that the power plug is properly connected, both to the POWER IN plug on the winch and to the mains power plug.
• Check that the fuse is tightly screwed into the fuse cap, also if it has just been changed.
• Check that the fuse is intact. It can be replaced with a new 2.0 A fuse.
• Check that the voltage selector is set to the correct voltage.

Regularly check the condition of the powerCON TRUE1 connector system (cable connector and chassis) for clear signs of wear and tear. Through improper use and excessive force, the encoding lugs and guide slots can become so worn or damaged that the cable connector can be inserted the wrong way. When inserted the wrong way, the connector should not twist-lock into place. A cable connector inserted the wrong way could in some circumstances lead to contact between live wires and the grounding contact in the plug socket.

• When connecting, match the notch on the cable connector to the corresponding guide slot on the chassis.
• After inserting properly, twist the cable connector clockwise to lock.
• The proper twist-lock is achieved when the silvery tab is in the position shown in illustration C on page 31 of the manual, and an audible “click” is heard.
• Immediately unplug any connector that does not twist-lock correctly in place.

The manual refers to the original Neutrik instructions in Appendix 2 (pages 33–34). Key points from those instructions:

• The powerCON TRUE1 system is intended to supply power to an appliance and from an appliance to other equipment. It is to be installed by a qualified person only.
• VDE approval (EN 60320-1 / EN 60320-2-2): 250 V ac / 16 A. Cable types: H05VV-F3G 1.0 mm² (length max. 2 m), H05VV-F3G 1.5–2.5 mm², H07RN-F3G 1.5 mm².
• UL approval (UL 498 / CSA C22.2 No. 182.3): 250 V ac / 20 A. Cable types: SJTOW, SJOOW 3 x 12 AWG.
• Strain relief: white chuck. Cable outer diameter (O.D.) listed in Appendix 2: 6.0–12.0 mm. Note: the main text on page 10 states an outer cable diameter of 6–16 mm.
• Cable preparation as shown in Appendix 2: 20 mm, 8 mm, and PE 23 mm.
• Wiring, VDE: L brown, N blue, ground green/yellow. Wiring, UL: L black, N white, ground green.
• Slide the cable into the contacts and clamp with the screw using Torx size T8, torque value 0.7 Nm.
• Torque value 2.0 Nm for tightening the cable clamp, wrench size 13 mm (tool available: Art. No. HTAC).
• Important: align the chuck by positioning the nose into the keyway. Important: the black O-ring must be hidden to achieve IP protection.
• Caution: to ensure the protection category, do not expose the connection to bending forces, for example by attaching loads to the cable or leaving free-dangling cable windings.
• Safety warning: for safety and certification reasons the connector must be replaced in case of any broken parts or excessive wear and tear.

A DMX 512 data link is required in order to control the winch 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 = (–), pin 3 = (+). Pins 4 and 5 are not used in the Winch 10 / Winch 3 but are available for possible additional data signals as required by the DMX512-A standard.

1. Connect the DMX data output from the DMX controller to the winch’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 output to input (DMX 512 OUT).
3. Terminate the last winch on the link with a 120 Ohm resistor.

The common limit of 32 devices per daisy-chained link applies. 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 limit is reached, add a DMX universe and another daisy-chained link.

• 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 is a male XLR plug with a 120 Ohm, 0.25 Watt resistor soldered between pins 2 and 3. It “soaks up” the control signal so it does not reflect and cause interference. If a splitter is used, terminate each branch of the link.

The DMX lamp is the green LED next to the DMX selectors.

• Glows constantly: DMX connection is correct.
• Flashes: DMX signal is missing or wrongly connected.

The DMX address, also known as the start channel, is the first channel used to receive instructions from the controller. It is set using the three DMX ADDRESS selectors on the winch (100., 10. and 1.). The selected address states from which channels on the lighting desk the winch is controlled. The address can be selected from 1 to 505. The Winch 10 / Winch 3 uses 7 DMX channels. For independent control, each winch must be assigned its own control channels.

Attention: the positioning run in MODE 2 works only when the winch has been reset.

Appendix 3 of the manual (page 35) contains a block diagram of the control system of the winch. In text, it shows:

• Input/output plugs: power out (PowerCON TRUE1), AC mains power input (PowerCON TRUE1), DMX signal in (XLR 5 pole) and DMX signal out (XLR 5 pole).
• Power supply: converts 230/115 VAC to 27 VDC and supplies the controller.
• Controller: receives the DMX signal (control input DMX signal) and has a manual control BCD switch input.
• Travel range limits: a top limit switch is connected to the controller.
• Load measuring: underload (slack detection) and overload (electrical measurement) are connected to the controller.
• Motor: the controller supplies motor power, and a position measurement on the motor reports back to the controller.

No. There is no dedicated emergency stop. The winch is controlled from a lighting desk, where it should always be set up with 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. The user can also stop the winch by disconnecting it from the mains. After a power failure the start position of the winch needs to be reset before the winch can function again.

The winch needs to be reset before the positioning MODE is possible. It can be reset manually or automatically. It must be reset each time its power supply has been disconnected.

Manual reset is done in MODE 2 on DMX channel 6. When the winch is ready, the first thing to do is to reset it.

• Set DMX channel 6 to 30 %: the winch starts to roll up the wire.
• When the snap hook approaches the motor-house, reduce the speed by reducing the channel 6 input. High speed can damage the winch and wire.
• Let it run until the snap hook at the end of the wire reaches the motor-house.

The winch is now reset, and the TOP limit is at the built-in motor-house top (10 cm below). If you want a lower soft TOP limit, see the soft TOP and BOTTOM limits section.

Warning: When resetting the winch in MODE 2, it is important to decrease the speed as the snap hook closes in on the motor-house, otherwise the wire and winch can be damaged.

When the winch has been reset and the TOP limit is set, it can be used for positioning runs.

• The position is set on DMX channels 1 and 2 (rough and fine position). 100 % is the soft TOP limit and 0 % is the soft BOTTOM limit.
• The speed is set on DMX channel 3, where 100 % is the fastest and 0 % is the slowest.
• The winch does not run unless channel 3 is set above zero. Channel 3 therefore also works as a main brake.

• Fast flashing: the winch needs to be reset before it can be used.
• Slow flashing: the winch’s load is moving towards the set position.
• Steady light: the set position has been reached and the motor has stopped.

1. Place or rig the winch in a truss or similar with a minimum clearance of 2–3 m (3–6 ft) below.
2. Put on a counterweight on the winch hook, minimum 0.45 kg (0.99 lb).
3. Set the DMX start address to 001 and the MODE to 2.
4. Apply DMX from a lighting desk, preferably with manual faders.
5. Make sure the 7 channels are patched from DMX channel 1 to 7.
6. Pull all channels to 0 %.
7. Apply power to the winch. The DMX lamp should be lit, and the mode lamp should be flashing.
8. Pull channel 6 to 20 %: the winch starts pulling the wire.
9. When the wire is at the hard TOP limit (pulled into the winch), stop the winch (set channel 6 to 0 %). The winch has now found its TOP position and is ready to drive with position control.
10. Pull channel 1 (position) to 95 %.
11. Pull channel 3 (speed) to 20 %. The winch starts to move down, with 20 % speed, to the 95 % up-position.
12. Pull channel 1 (position) to 80 %. The winch starts to move down, with 20 % speed, to the 80 % up-position.
13. Pull channel 1 (position) to 90 %.
14. Pull channel 3 (speed) to 50 %. The winch starts to move UP again, with 50 % speed, and stops 1 meter before the top.

The Winch 10 and Winch 3 should not be operated at a duty cycle higher than 30 % for longer periods of time. The duty cycle is the fraction of a period where the motor is active. Example from the manual: a maximum duty cycle of 30 % (10 min ON / 23 min OFF) means the motor may not be active more than 10 minutes every 33 minutes. After 10 minutes of ON, the motor must be OFF for 23 minutes.

The TOP limit needs to be reset, automatically or manually, before the winch can be used for positioning runs. The soft TOP and BOTTOM limits can be regulated to fit your needs.

• The TOP limit is reset manually with DMX channel 6. When the soft TOP limit is reset, it should always be set near the motor-house.
• The winch has a pre-set soft BOTTOM limit that is always 10 meters from the TOP limit. If the TOP limit is set far from the motor-house and the soft BOTTOM limit is not adjusted, the winch will still run 10 m (33 ft) down and eventually run out of wire. This activates the slack detection, and the winch will not go any further down.
• To avoid running out of wire, adjust the max travel to the soft TOP and BOTTOM limits on DMX channels 4 and 5.
• Examples from the manual’s diagram: channel 4 at 66 % is about 2 m from the top position. Channel 5 at 10 % is about 1 m from the bottom position.

Attention: If the two ranges overlap, the soft TOP limit overrules the soft BOTTOM limit. The winch will move down to that position but will be unable to be moved with normal positioning, because the operating range has been reduced to 0.

The best result is achieved by using a fading 16-bit position. The motors deviate slightly in performance, so some have a slightly higher maximum speed than others. Fading the position from one position to another over a certain amount of time, like fading conventional light, lets multiple winches follow the same fade curve.

1. Set the speed channel to 100 to gain the highest possible speed.
2. Assign the position channel as a 16-bit channel with MSB and LSB.
3. Make the speed of the fade slower than the maximum speed, so the motors have enough speed to follow the fade curve.

If the fade is too fast, the winches move at maximum speed and you will see the difference in motor speed. If the fade is too slow, the winches move – stop – move – stop when the position changes, giving a discontinuous movement.

Warning: Re-calibrating the overload affects the safety mechanisms of the winch. Violation of the maximum overload can cause a dangerous situation with risk of serious injury or death.

The winch is set to enter overload mode if it is loaded with more than the nominal load. The overload is a safety feature to ensure that the winch cannot lift more than what is safe. Overload detection is based on the motor current, which is affected by the efficiency of the gear. As the gear’s efficiency changes with usage, the overload may need re-calibrating. It is essential to test that the overload is correct at regular inspections. The overload can be re-calibrated to lower values as follows:

1. Ensure at least 1.5 m clearance below the winch.
2. Load the winch with the desired overload threshold weight + 10 % (max. 11 kg total for Winch 10 and max. 3.3 kg total for Winch 3).
3. Set the DMX channels to 999. Attention: when the mode is set to 9, the winch will start moving.
4. Then set the MODE to 9.

The winch will now run down several times. When the winch has moved back to the TOP limit, the overload has been re-calibrated. Ensure that you change the DMX channel and MODE away from 999 and 9 after re-calibration. Re-calibrating is only for service and tests.

• Read the safety information before servicing the winch.
• Disconnect the winch from AC mains power and allow it to cool down for at least 10 minutes before handling.
• Refer any service operation not described in the manual to a qualified service technician.
• The 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. Take the winch out of operation until the error is eliminated.
• Only parts ordered at or approved by Wahlberg should be used in the winch, to ensure product function and stability. Contact Wahlberg to inquire about spare parts.
• If the wire runs at an angle, performance degrades and the wire wears down faster, which shortens the lifetime of the wire significantly. Wire damage caused by mounting the winch at an angle is not covered by the product warranty. Figure 1 in the manual (page 23) illustrates the winch mounted at different angles: wire angle 0° and wire angle 10° (two examples).

The results of all regular inspections must be documented and kept available by the owner. The written result of the last inspection must be kept available at the site of operation, for example by an inspection sticker on the winch showing the date of the inspection, the basis of the inspection and the name of the inspector.

Before every use, and at least weekly while the winch is in use (every time when rigging the winch and before running it):

• Check that the winch is safely and correctly installed/mounted.
• Check that the winch’s load and LEDs are visible from the operating station.
• Check the entire length of the wire rope for bends, crushed areas, broken or cut cord, corrosion and other damage.
• Check all safety devices (slack detection, hard TOP limit).
• Check that the wire is wound neatly on the drum.
• Check the wire ferrule crimp and thimble.
• Check that the load is securely mounted.

Monthly, and at least every month while the winch is in use:

• Check the mounting clamp and loading hook for damage and proper fastening.
• Change damaged parts according to the manual.
• Check that the overload detection is correct.

Every 12 months: the winch must be inspected by a specialist.

Every 48 months: the winch should be inspected by an authorised expert.

Use the checklist before each use, each month and so on, in line with the maintenance plan.

• Check that the winch is safely and correctly installed/mounted.
• Inspect the entire length of the wire rope for bends, damage and wear, cut cords, corrosion and abuse.
• Inspect the wire ferrule crimp and thimble for damage, wear, corrosion or abuse.
• Secure that the load is safely attached and weighs max. 10 kg (22 lb) for the Winch 10 and max. 3 kg (6.7 lb) for the Winch 3.
• Check all limit switches.
• Check the slack detection device.

Warning: Do not use the winch if any damage or error is found.

Yes. On-site service and maintenance can be provided by Wahlberg Motion Design, giving owners access to Wahlberg Motion Design’s expertise and product knowledge. Contact Wahlberg Motion Design for details.

Winch 10 lifting wire: 2 mm (5/64 in) 7x7 galvanized steel wire (EN 12385-4). Minimum breaking load: 310 kg (3040 N / 683 lb). Wire safety factor: >10.

Maximum expected wire lifetime for the Winch 10, running up and down:

• At 2.5 kg (5.5 lb) load: up to 80,000 cycles.
• At 5.0 kg (11 lb) load: up to 20,000 cycles.
• At 10 kg (22 lb) load: up to 15,000 cycles.

The expected lifetime of the wire depends on the load, the travel length and the duty cycle. Wires are subject to wear and tear over the life of the product, and the extent depends heavily on operating conditions and environment, so it is impossible to specify precisely whether and to what extent the wire performance will be affected. The wire should be inspected long before these numbers are reached, checked for damage and replaced if necessary.

Winch 3 lifting wire: 2.3 mm coated 1.5 mm (5/64 in) 7x7 stainless steel wire (EN 12385-4). Minimum breaking load: 130 kg (1275 N / 287 lb). Wire safety factor: >10. Maximum expected wire lifetime: Pending.

If the wire gets damaged, stuck or has problems winding on and off, the wire and wire roll-up need to be inspected:

1. Disconnect the power.
2. Remove the 6x M3 hexagonal socket screws on one of the middle plates.
3. Take off the loose middle plate to look into the winch. Figure 2 in the manual (page 24) shows the Winch 10 (left) and Winch 3 (right) with a removed middle plate.
4. If the wire is not tight around the wire-wheel, or it is bundled up inside, it needs to be unravelled. This is done by manually unravelling and loosening the wire and pulling it out of the winch. It can be necessary to remove the other middle plate to work it out of the winch properly.
5. If the wire is bent or damaged, it must be replaced. See the wire discard criteria and the wire change procedure in this FAQ.
6. If the wire is okay, it must be rolled on again.
7. Mount the middle plate on the winch using the 6x M3 hexagonal socket screws and tighten them slightly.

Remember to always make a counterbalance in the wire when running the winch. According to the manual, a missing counterbalance is often the reason why the wire gets loose and tangled up.

When the wire rope is exposed, these guidelines can be used. If any of the discard criteria is reached, the winch must immediately be taken out of service and the wire replaced before the winch is used again. Discard the wire rope when:

• The overall diameter of the rope is reduced by 8 %, or the outer wires have lost 33 % of their diameter through wear. Measure the reduction on a portion of the rope that has been subjected to abrasion and stresses, relative to a portion subjected to stresses but not abrasion, for example portions near the drum or anchorage.
• There is evidence of considerable plastic wear or surface embrittlement.
• The diameter of the rope has suddenly reduced, or the lay length has suddenly increased or decreased.
• There is evidence of severe corrosion, like chain pitting.
• There is any evidence of internal corrosion in the rope. This can be recognized by slackness of outer wires due to the internal wires corroding away.
• The rope has been subjected to mechanical damage, crushing, kink, bends, bird cage and similar.
• The core of the rope has collapsed.
• The rope has been subjected to a high temperature or heat due to fire.
• The rope has been subjected to severe shock load or overload due to an accident with the winch.

When using a calliper to measure the wire rope diameter, measure from crown to crown, not from valley to valley (Figure 3 in the manual, page 25, shows a correct and an incorrect calliper position).

If the wire has any damage, the winch must not be used until the wire has been replaced. This can be done following the instructions below, or by Wahlberg. Contact Wahlberg Motion Design for information regarding approved spare parts and questions about the procedure. The manual (pages 26–30) has photos of the stages.

1. Roll off the wire: Set the winch to MODE 8 (manual roll down). Pull down on the wire to deactivate the slack detection. Continue pulling until all the wire has been rolled off the winch. Cut off the old wire using a steel rope cutter.
2. Disconnect the power.
3. Remove the 6× M3 hexagonal socket screws on each middle plate on the winch.
4. Take off the two loose middle plates to access the wire mount.
5. Remove the end frame and plate by removing the four M4 hexagonal socket screws.
6. Remove the four hexagonal spacers and the two bolts holding the TRAFO-plate.
7. Remove the two bolts and nuts holding the mounting plate and the TRAFO-plate together.
8. Take the PVC tube out of the transformer plate.
9. Carefully lift off the transformer plate and tilt it. Ensure that none of the wires and plugs is damaged during this operation.
10. Take out the wire-wheel and cut off the wire-eye of the old wire, allowing the old wire to be removed.
11. Cut off 10.6 m of 2 mm 7x7 galvanized steel wire rope (approved by Wahlberg).
12. Put the new wire through the ‘top stop’ and through the hole in the wire-wheel.
13. Form an eye with the new wire and a ferrule (approved by Wahlberg), using the old eye as a template.
14. Place the eye over the axle of the wire-wheel.
15. Mount the wire-wheel back on the winch. You might need to take out the slack detection to make it fit in.
16. Ensure that the spacing washer for slack detection is installed.
17. Assemble the winch by placing the transformer plate on top of the wire-wheel. Ensure that the ‘top stop’ and slack detection are correctly mounted.
18. Tighten the bolts and nuts for the mounting bracket. Check that you use the right bolts, by ensuring that the bolt goes through the nut and self-locks.
19. Mount the four hexagonal spacers and the two bolts holding the transformer plate.
20. Ensure that the ‘top stop’ and slack detection spring are correctly mounted.
21. Hereafter the wire must be rolled on. See “How do I apply (roll on) the wire?” below.
22. When the wire end is approx. 30 cm away from the ‘top stop’, stop the wire roll up. Place the top bead (wire stop) on the wire and make an eye using thimble and ferrule (approved by Wahlberg). Ensure to use appropriate swaging or crimping tools. Attention: the wire stop is essential for the function of the winch. Forgetting the spring will damage the winch.
23. Roll up the last bit of the wire.
24. Mount the middle plates on the winch again and fasten each with the six 3 mm hexagonal socket screws. Tighten them slightly.

Warning: Be careful not to touch the power supply inside the winch, as it is exposed. This can cause an electric shock and damage you and the winch. Be careful not to get fingers, hair, clothes or similar caught in the wire-wheel as it turns. This can damage you and the winch.

1. Set the MODE to MODE 0 (neutral), to make sure the motor does not start inadvertently when the power is connected.
2. Connect the power.
3. Set the DMX start address to zero (000).
4. Set the MODE to manual up (MODE 7).
5. Set the speed on the DMX address. The suggested address is 100, which is a fine, slow speed that is easy to follow.
6. Using a glove, hold the wire firmly to ensure it is rolled up tightly around the wire drum. Attention: keep the wire stretched tight until it is all rolled up, to ensure that the wire is rolled up tightly around the wire-wheel. Make sure not to bend or damage the loose wire as it rolls on.
7. When the wire has rolled on all the way, disconnect the power or set the speed (DMX start address) to zero (000).

When the wire has been applied to the winch again, it is good practice to run it up and down a couple of times before assembling it again. Remember always to make a counterbalance in the wire when running the winch, as a missing counterbalance is often the reason why the wire gets loose and tangled up in the first place.

• The product is for professional use and presents risks for severe injury or death.
• Always warm up electronic equipment to room temperature before applying power.
• Isolate the product from power immediately if it is defective or shows signs of overload. Do not reapply power until repairs have been completed.
• Do not modify the product in any way not described in the manual.
• Refer any service operation not described in the manual to a qualified technician.
• Install only genuine Wahlberg Motion Design parts.

• Fasten the product securely to a fixed surface, rig or structure as described in the manual.
• Ensure that any supporting hardware can hold at least 10 times the weight of all the devices it supports.
• 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 the manual must always be followed.

• 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.
• The winch must be grounded (earthed).

• 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.
• If the surface temperature exceeds 70 °C (194 °F), there is a risk of damaging the winch.

No. The Winch 50 Series is intended for indoor use only. Do not expose it to rain.

The winch is for stage use, mainly in theatres, shows and concerts. It is designed for lifting and lowering material at the weight and speed stated in the technical specifications. Any other use may result in a risk of injury of persons or equipment damage. Exceeding the load rating may cause failure of the equipment.

• The lifting capacity is 50 kg (110.2 lb).
• Use only mounting connectors approved by Wahlberg Motion Design to secure the load to the winch.
• 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.

The winch 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 stops when the speed is set to 0 %. Contact Wahlberg Motion Design for further information and education on the DMX protocol. Manual operation of the winch is only intended for installation, service and tests.

The control system ensures that the motor is only 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.
• There is no overload.

• Lifting capacity: 50 kg (110.2 lb).
• Lifting height: 12.5 m (41 ft) for 245.3, 246.4 and 246.5. For 245.4: 9.7 m (31.8 ft) on the wire version and 4 m (13.1 ft) on the power version.
• Lifting speed: 3–100 cm/s (1.2–39.4 in/s) for 245.3, 246.4 and 246.5. 1–45 cm/s (0.4–17.7 in/s) for 245.4.
• Minimum load: 5 kg (11 lb) for 245.3, 246.4 and 246.5. No minimum load is needed for 245.4.

• Power supply: 208–240 V AC, 50–60 Hz.
• Power consumption: 825 W (4.0–3.5 A).
• 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).
• Motor: 230 V AC, 0.55 kW.
• Noise emission: ~50 dB.
• Ambient temperature: 5–40 °C (32–104 °F) as listed in the specifications.
• Mounting clamp: 4× slim eye coupler, 42–52 mm (2 in).

• 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 (246.4 only).
• 1× powerCON NAC3MX-W-TOP male plug for power output from bar (246.4 only).
• 1× User manual.
• 1× Cheat sheet.

Protect the winch from physical shocks and vibration during transportation and storage. Before applying power:

• Check www.wahlberg.dk for the most recent documentation and technical information about the product. User manual revisions are identified by the revision number at the bottom of each page.
• Carefully review the safety information on page 2 of the manual.
• Check that the local AC mains power source is within the power voltage and frequency ranges.
• Install the provided Neutrik powerCON TRUE1 NAC3FX-W-TOP power connector on a suitable power cable. If using power from a mains power outlet, install a suitable power plug on the power cable.

• Roll the wire up and fix it with a cable tie or an elastic cord. If the wire is slack, it may jump off the drum during transport and damage the winch.
• Protect the winch from physical shocks and vibration during transportation.
• Use only the original packaging or a flight case. Contact Wahlberg Motion Design for enquiries regarding flight cases or pallet frames.

The winch must be either fastened to a flat surface such as a roof, or clamped to a truss or similar structure, so that the wire exit points downwards. Do not apply power if the product is not securely fastened.

• The supporting surface must be hard and flat, and able to support at least 10 times the weight of all products and equipment installed on it.
• Use only the supplied rigging clamps.
• Make sure the wire exit point is straight downwards to maintain the expected lifetime of the wire.

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 2 supplied slim couplers on the top plate. Both must be used, because the load is not evenly distributed across the product.
4. Install suitable safety cables when the product is hanging overhead, and verify that this complies with either EN 60598-2-17:2018 section 17.7.4 or BGV C1/DGUV 17.

• The load must be mounted on the wire so that it can never run into the winch.
• The load can be mounted using a suitable loading hook designed for lifting.
• The loading hook must have a minimum breaking load of at least 500 kg.

Yes. Before running the winch, put a counterbalance on the wire, because the slack detection switch will otherwise activate and stop the winch. The minimum load is 5 kg (11 lb) for 245.3, 246.4 and 246.5. No minimum load is needed for 245.4.

Because of the way the winch rolls up the wire, the point where the wire comes out of the winch changes depending on how much wire has been rolled out. The wire moves approx. 80 mm sideways from the hard TOP limit to the hard BOTTOM limit. The 245.4 has no wire fleet.

• A power input cable with a Neutrik powerCON TRUE1 NAC3FX-W(-TOP) cable connector for AC mains input.
• The cable must be rated 20 A minimum, have three conductors of 1.5 mm² (AWG 16) minimum conductor size, and an outer cable diameter of 6–16 mm (0.24–0.47 in).
• Cables must be heat resistant to 90 °C (194 °F) minimum.
• In the EU the cables must be <HAR> approved or equivalent. 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 rated 20 A for USA and 16 A for Europe. Follow the plug manufacturer’s instructions.
• To install a powerCON TRUE1 connector, follow the original Neutrik instructions in the appendix to the manual (page 43).

If pins are not clearly identified, or if you have any doubts about proper installation, consult a qualified electrician.

• 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.
• Socket outlets or external power switches used to supply the product must be located near the equipment and be easily accessible, so it can easily be disconnected from power.
• Check that the voltage range on the serial number label matches the local AC mains voltage. Do not apply AC mains power at any other voltage than specified.

The display shows a start-up sequence with the product name, then the software version, then a description of how to enter the menu. Before the winch is ready to be controlled by DMX, channel 4 must be re-enabled. After that it is ready to be operated.

• Regularly check the connector system (cable connector and chassis) for clear signs of wear and tear.
• Through improper use and excessive force, the encoding lugs and guide slots can become so worn or damaged that the cable connector can be inserted the wrong way. When inserted the wrong way, it should not twist-lock into place.
• A cable connector inserted the wrong way could in some circumstances lead to contact between live wires and the grounding contact in the plug socket.
• Listen for the “click” when performing the twist-lock. Immediately unplug any connector that does not twist-lock correctly in place.

• The lifting wire requires a power input through a Neutrik powerCON NAC3FX-W-TOP cable connector.
• Power through: 16 A / 240 V AC, 2×1.5 mm² (AWG 16). Signal through: two twisted pairs Cat5 (100 Mbit/s).
• Socket outlets or external power switches used to supply the lifting wire attachment must be located near the winch and be easily accessible.
• Check that the voltage matches the range specified for the lifting wire before applying power. Do not apply power at any other voltage than specified in the manual.
• To install the powerCON TRUE1 cable connector, follow the original Neutrik instructions in the appendix to the manual (page 43).

A DMX 512 data link is required to control the winch 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 = (–), pin 3 = (+). Pins 4 and 5 are not used in normal operation and are available for additional data signals as required by the DMX512-A standard. They can also be used to feed back the actual position of the winch, but then the port is not suitable for daisy chaining.

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 product to the DMX input of the next product, and continue connecting output to input (DMX 512 OUT).
3. Terminate the last product on the link with a 120 Ohm resistor.

The common limit of 32 devices per daisy-chained link applies. If independent control of a winch is required, it must have its own DMX channels. Products that are required to behave identically can share the same DMX channels. To add more products or groups of products when the limit is reached, add a DMX universe and another daisy-chained link.

• 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 is a male XLR plug with a 120 Ohm, 0.25 W resistor soldered between pins 2 and 3. If a splitter is used, terminate each branch of the link.

• DMX LED (green, above the display), glows constantly: DMX connection is correct.
• DMX LED flashes: the DMX signal is missing or wrongly connected.
• Error LED off: no errors on the winch.
• Error LED on (red): an error is detected. See the error description on the display. Reset an error by setting DMX channel 4 to 0 %.

The DMX address, also known as the start channel, is the first channel used to receive instructions from the controller. It is set in the menu under DMX ADDRESS, in the range 1–506. For independent control, each product must be assigned its own control channels.

When channel 5 or 6 returns to 0 %, the drum returns to the current wanted position given by channels 1 and 2, provided the unit has a valid soft BOTTOM limit and the speed on channel 3 is not zero.

Yes, with the POS OUT setting in the advanced menu. The position feedback outputs a DMX signal on pins 1, 4 and 5 of the DMX in/out plugs. All values are zero except the feedback, which is located at the DMX address of the device. If the winch has start channel 73, the 16-bit feedback is at channels 73 and 74.

• OFF: no output.
• SCALE: 16-bit scaled feedback, 0,0 at the bottom and 255,255 at the top.
• DIV 4: 16-bit raw feedback divided by 4, 0,0 at the bottom and TAC RANGE divided by 4 at the top. For a 10 meter span this is roughly 77,104.
• 32BIT: 32-bit raw feedback, 0,0,0,0 at the bottom and TAC RANGE at the top. For a 10 meter span this is roughly 0,1,53,161.

It can be configured with an optional emergency stop switch. By default, the emergency stop is NOT enabled. The DMX control from a lighting desk should always be set up with a button that sets the speed of the winch in operation to 0 %. Normally lighting desks have a “blackout” button that sets all intensity channels to 0 %, and this will also stop the winch when assigned correctly.

The switch is connected to the male 4-pole XLR connector on the winch. Pin 1 and pin 4 must be powered with 12–15 V DC to enable operation of the winch.

1. Enter the menu navigation mode.
2. Change E STOP from OFF to ON.
3. Connect the winch to power, DMX and the emergency stop switch. It can then be controlled from the lighting desk.

To get the full functionality of the emergency stop, a wire has to be plugged in inside the winch, as described in the manual. The emergency stop power supply and plug are available from Wahlberg Motion Design.

The red Error LED lights and the display shows ‘EMERGENCY STOP PRESSED’ and the current start channel of the unit.

Use the arrow buttons at the display to go up or down in the menu, and the buttons beside them to set values and go back one level. Press and hold both the up and down arrow for 1 second to enter and leave menu navigation mode. In this mode the motor is stopped and DMX input has no effect, but the motor can be moved with the manual run menu.

In control mode, the display shows the current position (P), wanted position (W), distance to wanted position (D) and speed in motor RPM (S). A further screen shows the DMX channel values.

Press the set button, then press and hold it. The top line of the display counts up to 20 and then shows OK. The value is now saved in the memory.

• RAMP TIME is the time the winch takes to accelerate from a standstill to maximum speed, and decelerate from maximum speed to a standstill when positioning.
• SPEED MAX sets the maximum speed. At 1000, the motor runs at 1000 RPM when DMX speed is set to full. To convert, multiply the speed in cm/s by 59.4, for example 50 cm/s × 59.4 = 2970 RPM.
• Newer winches reach up to 100 cm/s for certain weights. Running at these extreme speeds lowers the maximum duty cycle and should be thoroughly tested before a live performance.
• SP MIN UP and SP MIN DWN set the motor minimum speed for each direction. Set each to a speed where the motor still runs at full load.

Be extra cautious when changing these values, since some combinations may lead to dangerous movement and damage to the unit or attached equipment.

• SLACK DELAY: a delay in pulses from slack activation until the winch registers it and tries to stop. Can be used if the load is around the minimum load and slack is bouncing.
• UNSAFE MODE: should only be used in emergency situations. It disables both limit switches, slack and emergency stop, and makes the error LED blink.
• REVERSE DIR: reverses motor movement, encoder and limit switch direction.
• QUICK SLACK: stops the winch quickly if slack is enabled. If the load is light or fast accelerations are used, slack may be activated by accident, leading to a stuttering movement.
• PRECISION: the tolerance in which the winch stops. Too small a precision leads to the winch overshooting its wanted position and never stopping, which overheats the motor and eventually damages it.
• NOM. FREQ: the frequency of the national grid of the installation.
• SLS RESET: sets all since-last-service values to zero. Go through all service steps described in the manual first.

• Soft limits are entirely software controlled and limit the working range for a given application or show. They are saved automatically when a setup procedure is started with DMX channel 5 or 6.
• Hard limit switches set the maximum and minimum travel distance of the winch. They make a click sound when pressed or released, and the display shows when one is activated.
• The hard limits are factory pre-set to stop 3 cm below the winch and have a travel length of 12.5 m.

The soft TOP limit must always be set before the soft BOTTOM limit.

1. Set DMX channel 5 to 30 % and wait 3 seconds. The winch moves up towards its hard TOP limit. Set channel 5 to 0 % at the wanted position. This is now the soft TOP limit.
2. Set DMX channel 6 to 30 % and wait 3 seconds. The winch moves down towards its hard BOTTOM limit. Set channel 6 to 0 % at the wanted position. This is now the soft BOTTOM limit.

When both are set, the internal range (TAC RANGE) is calculated. It is the number of encoder pulses between the soft TOP and soft BOTTOM limits, which correlates to the 0 % and 100 % positions on channels 1 and 2.

Warning: There must be at least 2 rounds left on the drum when the winch is adjusted for the soft BOTTOM limit. Also make sure the load cannot cause injury or hit any obstacles in the moving range.

Caution: Do not set the hard TOP limit where the load can run into the winch itself, as this will damage the winch.

1. Put the winch in manual mode while adjusting the limits.
2. Locate the hard limit switch box, the black box just in front of the fan.
3. Loosen the two screws holding the lid.
4. Loosen the middle screw.
5. Adjust the hard BOTTOM limit by turning the screw with a 1 next to it.
6. Adjust the hard TOP limit by turning the screw with a 2 next to it.
7. When adjustments are done, tighten the middle screw again.
8. Mount the lid with the two screws again.

It is not advisable to adjust the hard TOP limit closer to the winch than 3 cm. For software versions before 503.001.012, the stopping distance was longer, and the hard TOP limit should not be closer to the winch than 10 cm.

1. Place or rig the winch with a minimum of 2 meters of clearance below.
2. Load the wire with a minimum load of 5 kg (11 lb). No load is needed for 245.4.
3. Connect the mains and emergency switch (if enabled), and make sure the error LED is no longer glowing red. The winch turns on and the display shows the start-up message.
4. Set the DMX start address to 1 and apply DMX from a lighting desk, preferably with manual faders. Make sure the 6 channels are patched from DMX channel 1 to 6. Pull all channels to 0 %.
5. Set DMX channel 4 between 50 % and 55 %. The motor is now enabled and the winch can run.
6. Set DMX channel 5 to 30 % and wait 3 seconds. The winch moves up towards its hard TOP limit. Set channel 5 to 0 % to stop when desired or at the hard TOP limit. This position is now the soft TOP limit.
7. Set DMX channel 6 to 30 % and wait 3 seconds. The winch moves down towards its hard BOTTOM limit. Set channel 6 to 0 % to stop when desired or at the hard BOTTOM limit. This position is the soft BOTTOM limit.
8. Set DMX channel 1 to 100 % and DMX channel 3 to 20 %. The winch moves with 20 % speed to the 100 % position.
9. Set DMX channel 1 to 90 % and DMX channel 3 to 50 %. The winch moves with 50 % speed to the 90 % position.
10. Before shutting down, set DMX channel 4 to 0 % to save the current position. When the winch powers on, it recalls its position and limits and is ready to position.

Set DMX channel 4 to 0 % before a regular power down. This saves the current position, and the unit is ready to position when powered on. If it is not saved before shutdown, the soft TOP limit must be set again when the unit is powered on.

The winch should not be operated at a duty cycle higher than 30 % for longer periods of time. The duty cycle is the fraction of a period where the motor is active. Example from the manual: a maximum duty cycle of 30 % (10 min ON / 23 min OFF) means the motor may not be active more than 10 minutes every 33 minutes. After 10 minutes of ON, the motor must be OFF for 23 minutes.

The load impacts the minimum speed the winch can operate at. At heavy loads, the minimum speed up must be increased to a point where the winch can still move. With a light load and high minimum speeds, the winch might have problems finding its position. In that case, lower the minimum speeds. The minimum speed is adjusted in the menu.

The best result is achieved by using a fading 16-bit position. The motors deviate slightly in performance, so some have a slightly higher maximum speed than others. Fading the position from one position to another over a certain amount of time, like fading conventional light, lets multiple winches follow the same fade curve.

1. Set the speed channel to 100 % to gain the highest possible speed.
2. Assign the position channel as a 16-bit channel with MSB and LSB.
3. Make the speed of the fade slower than the maximum speed, so the motors have enough speed to follow the fade curve.

If the fade is too fast, the winches move at maximum speed and you will see the difference in motor speed. If the fade is too slow, the winches move – stop – move – stop when the position changes, giving a discontinuous movement.

• Display shows nothing: check that the winch is connected to mains power and that the fuse in the winch is intact.
• DMX lamp is blinking: check the DMX signal.

Manually lower the wire totally off the drum, while inspecting that the wire comes out of the winch evenly. Afterwards, roll the wire back onto the drum and reset the top position.

• “Not in Pos”: the winch cannot move to its position. This usually occurs when the load is high. Go into the menu and increase the minimum speed up.
• “NO MOVEMENT DETECTED”: the winch continuously does not measure any movement when trying to move. Check that nothing has caught, and if not, go into the menu and increase the minimum speed up.

The winch stops at power failure. When the power is re-established, the winch must be reset before it is ready to use. It is advisable to set all DMX channels to 0 % before the power is re-established.

Set DMX channel 4 to 0 %. When the Error LED lights red, there is also an error description on the display. When an error occurs, the control system shuts down the motor and issues an error code.

“Power cycle” below means: unplug the power, wait 30 seconds, and apply power again. Consult an authorized service technician if the failure keeps coming.

Appendix 6 of the manual (page 45) contains a block schematic of the control system. In text, it shows:

• Input/output plugs: power in 208–240 V AC and power out (powerCON TRUE1), emergency stop, DMX signal in and out (XLR 5 pole). 245.4 and 246.4 also have power in and Cat5 in for the bar (powerCON TRUE1, etherCON), and power out and Cat5 out for the bar.
• Power supply and motor controller, with a controller receiving the DMX signal and a manual control input.
• Travel range limits: top hard limit and bottom hard limit.
• Load measuring: slack detection (underload) and overload (electronic).
• Drive train: motor, gear, encoder and slip rings.

• Read the safety information before servicing the winch.
• Disconnect the winch from AC mains power and allow it to cool down for at least 10 minutes before handling.
• Refer any service operation not described in the manual to a qualified service technician.
• The 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. Take the winch out of operation until the error is eliminated.
• Only parts ordered at or approved by Wahlberg Motion Design should be used. Contact Wahlberg Motion Design to inquire about spare parts.
• If the wire runs at an angle, performance degrades and the wire wears down faster, which shortens the lifetime of the wire significantly. Wire damage caused by mounting the winch at an angle is not covered by the product warranty.

The results of all regular inspections must be documented and kept available at the company. The written result of the last inspection must be kept available at the site of operation, for example by an inspection sticker on the winch showing the date of the inspection, the basis of the inspection and the name of the inspector.

Before every use, and at least weekly while the winch is in use (every time when rigging the winch and before running it):

• Check that the winch is safely and correctly installed/mounted.
• Check that the winch’s load and LEDs are visible from the operating station.
• Check the entire length of the wire for bends, crushed areas, broken or cut cord, corrosion and other damage.
• Check all safety devices (slack detection, limit switches, emergency stop).
• Check that the wire is wound neatly on the drum.
• Check the wire ferrule crimp and thimble.
• Check that the load is securely mounted.

Monthly, and at least every month while the winch is in use:

• Check the mounting clamps for damage and proper fastening.
• Change damaged parts according to the manual.
• Check that the overload detection is working.

Every 12 months: the winch must be inspected by a specialist.

Every 48 months: the winch should be inspected by an authorised expert.

Use the checklist before each use, each month and so on, in line with the maintenance plan.

• Check that the winch is safely and correctly installed/mounted.
• Inspect the entire length of the wire rope for bends, damage and wear, cut cords, corrosion and abuse.
• Inspect the wire ferrule crimp and thimble for damage, wear, corrosion or abuse.
• Check that the load is safely attached and weighs max. 50 kg (110.2 lb).
• Check safety functions (limit switches, slack detection and emergency stop).
• Check that the wire is wound neatly on the drum.
• Make sure that the operator has visual confirmation of all possible movements of the winch at all times.

Warning: Do not use the winch if any damage or error is found.

Yes. On-site service and maintenance can be provided by Wahlberg Motion Design, giving owners access to Wahlberg Motion Design’s expertise and product knowledge. Contact Wahlberg Motion Design for details.

• 245.3, 245.4 (wire version), 246.4 and 246.5: 3 mm (1/8 in) 19x7 galvanized steel wire (EN 12385-4). Minimum breaking load: 590 kg (5786 N / 1301 lb).
• 245.4 (power version): 6.5 mm (1/4 in) 8x17 galvanized steel wire (EN 12385-4). Minimum breaking load: 2230 kg (21869 N / 4916 lb).
• Wire safety factor: >10. Wire angle: none.

The expected lifetime of the wire depends on the load, the travel length and the duty cycle. Wires are subject to wear and tear over the life of the product, and the extent depends heavily on operating conditions and environment, so it is impossible to specify precisely whether and to what extent the wire performance will be affected.

When the wire is exposed, these guidelines can be used. If any of the discard criteria is reached, the winch must immediately be taken out of service and the wire replaced before the winch is used again. Discard the wire when:

• The overall diameter is reduced by 8 %, or the outer wires have lost 33 % of their diameter through wear. Measure the reduction on a portion that has been subjected to abrasion and stresses, relative to a portion subjected to stresses but not abrasion, for example portions near the drum or anchorage.
• There is evidence of considerable plastic wear or surface embrittlement.
• The diameter has suddenly reduced, or the lay length has suddenly increased or decreased.
• There is evidence of severe corrosion, like chain pitting.
• There is any evidence of internal corrosion. This can be recognized by slackness of outer wires due to the internal wires corroding away.
• The wire has been subjected to mechanical damage, crushing, kink, bends, bird cage and similar.
• The core of the wire has collapsed.
• The wire has been subjected to a high temperature or heat due to fire.
• The wire has been subjected to severe shock load or overload due to an accident with the winch.

When using a calliper to measure wire diameter, measure from crown to crown, not from valley to valley.