Winch 10 - Wahlberg Motion Design

Roll Down
Item No 249
User Manual
WWW.WAHLBERG.DK
TELEPHONE: +45 86 18 14 20
EMAIL: sales@wahlberg.dk
AXEL GRUHNS VEJ 3
8270 HØJBJERG
DENMARK
Safety Information
The following symbols are used to identify important safety information on the product
an in this manual:
This product is for professional use only. It is not for household use.
This product presents risks for severe injury or death due to fire hazards, electric
shock, and falls.
Read this manual before installing, powering or servicing the Roll Down; follow the
safety precautions listed below and observe all warnings in this manual and printed on
the Roll Down. If you have questions about how to operate the Roll Down safely, please
contact you Wahlberg Motion Design supplier or Wahlberg Motion Design.
PROTECTION FROM ELECTRIC SHOCK
− Disconnect the Roll Down from AC power before removing or installing any
cover or part and not when in use.
− Always ground (earth) the Roll Down electrically.
− Use only a source of AC power that complies with local building and electrical
codes and has both overload and ground-fault (earth-fault) protection.
− Before using the Roll Down, check that all power distribution equipment and
cables are in perfect condition and rated for the current requirements of all
connected devices.
− Power input throughput cables must be rated 20 A minimum, have three
conductors 1.5 mm2 (AWG16) minimum conductor size and an outer cable
diameter of 5-15 mm (0.2-0.6 inch). Cables must be hard usage type (SJT or
equivalent) and heat-resistant to 90°C (194°F) minimum. In the EU the cables
must be <HAR> or equivalent.
− Use only Neutrik powerCON TRUE1 NAC3FX-W cable connectors to connect to
power input sockets.
− Assembly power supply cables following the instructions in this manual only
(see page 17).
− Isolate the Roll Down from power immediately of the power plug or any seal,
cover, cable, or other component is damaged, defective, deformed, wet, or
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−
−
showing signs of overheating. Do not reapply power until repairs have been
completed
Do not expose the Roll Down to rain or moisture.
Refer any service operation not described in this manual to a qualified
technician.
PROTECTION FROM BURNS AND FIRE
− Do not operate the Roll Down if the ambient temperature exceeds 40° C (104°
F).
− Do not modify the Roll Down in any way not described in this manual.
− Install only genuine Wahlberg parts.
PROTECTION FROM INJURY
− Fasten the Roll Down securely to a fixed surface, rig, or structure when in use.
The Roll Down is not portable when installed.
− Ensure that any supporting structure and/or hardware can hold at least 10
times the weight of all the devices they support
− If suspending from a rigging structure, fasten the Roll Down using the supplied
4× Manfrotto slim coupler according to the manual, see page 12.
− Always install the Roll Down as described in this manual. If the Roll Down is
installed in a location where it may cause injury or damage if it falls, install as
described in 12.
− If possible, allow enough clearance beneath the Roll Down so it cannot cause
any danger to personnel beneath it. Alternatively, adjust the lower limit
accordingly following the instructions in this manual.
− Check that all external cobblers and rigging hardware are securely fastened.
− Block access below the work area and from a stable platform whenever
installing, servicing or moving the Roll Down.
− Do not operate the Roll Down with missing or damaged covers, shields, or wire.
− Do not use the Roll Down over the head of people
− Do not use the Roll Down to lift people or animals.
Before each use
−
−
−
−
−
−
Inspection points!
249.805.009
Check that the Roll Down is safely and correctly installed.
Inspect the entire length of the tube for bends, damage,
wear, corrosion, and abuse.
Inspect the fabric attachment for damage, wear, or abuse.
Check that the fabric weighs maximum 35 kg.
Check all safety devices (limit switches, and emergency stop)
Make sure that the operator has visual confirmation of all
possible movements of the Roll Down at all time.
Warning!
Do not use the Roll Down if any damage or error is found!
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Disposing of this product
Wahlberg Motion Design products are supplied in compliance with Directive
2002/96/EC of the European Parliament and of the Council of the European
Union on WEEE (Waste Electrical and Electronic Equipment), as amended
by Directive 2003/108/EC, where applicable.
Help preserve the environment! Ensure that this product is recycled at the
end of its life. Your supplier can give details of local arrangements for the
disposal of Wahlberg Motion Design products.
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Index
SAFETY INFORMATION
2
INDEX
3
TECHNICAL SPECIFICATIONS
6
DRAWING
7
INTRODUCTION
8
PACKAGE CONTENT ......................................................................................... 8
DESCRIPTION................................................................................................ 8
SAFETY FUNCTIONS ......................................................................................... 9
AREA OF USE ................................................................................................ 9
USING FOR THE FIRST TIME .................................................................................. 9
TRANSPORT ................................................................................................11
PHYSICAL INSTALLATION
12
FASTENING THE ROLL DOWN TO A FLAT SURFACE...........................................................12
MOUNTING THE ROLL DOWN ON A TRUSS ...................................................................12
MOUNTING THE TUBE ......................................................................................13
AC POWER
16
POWER CABLES AND POWER PLUG ..........................................................................16
INSTALLING A POWER INPUT CONNECTOR ON A POWER CABLE ...............................................17
DATA LINK
18
TIPS FOR RELIABLE DATA TRANSMISSION ....................................................................18
CONNECTING THE DATA LINK ...............................................................................18
EMERGENCY STOP SWITCH (OPTIONAL)
19
ENABLE EMERGENCY STOP .................................................................................20
READY TO USE .............................................................................................20
SETUP
21
MENU SETTING .............................................................................................21
MENU STRUCTURE..........................................................................................22
ADJUSTABLE PARAMETERS ..................................................................................25
DETAILED EXPLANATION OF PARAMETERS ...................................................................26
DMX ADDRESS SETTING ..................................................................................26
ADJUSTING HARD LIMIT SWITCHES ..........................................................................28
NORMAL OPERATION .......................................................................................30
SYNCHRONIZED MOVEMENTS OF MULTIPLE ROLL DOWNS ....................................................31
LED FUNCTIONS ...........................................................................................32
ERROR AND ERROR CODES: .................................................................................32
SERVICE AND MAINTENANCE
35
PARTS .....................................................................................................35
ON-SITE SERVICE ...........................................................................................35
MAINTENANCE PLAN ........................................................................................36
CHECKLIST .................................................................................................36
APPENDIX 1
37
APPENDIX 2
39
APPENDIX 3
41
ROLL DOWN - CHEAT SHEET
42
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Technical specifications
Model:
Item no.:
Dimensions (L×W×H):
Motor clamp
Tube
Power supply:
Power consumption:
Power inlet:
DMX control signal:
DMX connection:
Lifting height:
Lifting capacity:
Lifting speed:
Minimum load:
Noise emission:
Ambient temperature:
Own weight:
Motor clamp
Tube
Mounting clamp:
Motor:
Duty cycle:
249.805.009
Roll Down
249
81.6 × 230 × 345 mm (3.2 × 9.1 × 13.6 in)
Ø200 × 1500-12000 mm (Ø7.87 × 59.1-472.4 in)
200-240V AC 50-60 Hz
500 Watt
Neutrik powerCON TRUE1 NAC3PX (F/M)
DMX 512 1990 + DMX512A / 6 channels used
5 pole XLR, male & female
18 m (59 ft.) Limit set to 15m as default!
35 kg (77 lb)
Variable, 0.05-1.0 m/s (2.0-39.3 in/s)
None
~70 dB
0-40°C (32-104°F)
40 kg (88.2 lb)
5.1 kg/m (3.43 lb/ft.)
4× Slim eye coupler 50 mm (2 in)
230V AC, 0.55 kW 2800 rpm
Maximum 30% at max. load (refer to page 30)
Minimum 23 min OFF after 10 minutes ON
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Drawing
Roll Down (249)
More detailed drawings and from more angles can be found in Appendix 1 on page 37
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Introduction
Thank you for selecting the Roll Down, a DMX controlled Roll Down from Wahlberg
Motion Design. Before using the Roll Down for the first time, please read this manual
carefully. Failure in handling can cause injury of persons and/or damage the Roll
Down.
Package content
1×
1×
1×
1×
Roll Down
PowerCON NAC3FX-W female plug for power cable
User manual
Cheat sheet
Description
Roll Down is a Roll Down for stage use, mainly for use in theatres, shows and concerts.
It lifts fabrics in and out of the stage sphere at a maximum load of 35 kg up and down.
The lifting height is 15 m (can be extended to 18 m). The lifting speed is between 5
cm/s and 100 cm/s.
The Roll Down is controlled by the standard DMX controlling signal, so a normal lighting
desk can be used to control the movement, programmed as normal light.
For a low number of Roll Downs, a standard lighting desk can be used, but when many
Roll Downs are used, more advanced desks should be used to maintain easy control of
the units.
The Roll Down uses 6 channels of the DMX-line, and they control the position, speed,
limits, and reset functions.
The Roll Down has an advanced internal positioning system with 16 bit, used for finding
the position desired by the operator. With a 16 bit positioning channel (ch1 and ch2)
the operator set the desired position, and the Roll Down will run to this position, with
the speed applied on the speed channel (ch3).
Channel 4 is used to enable power.
With channel 5 and 6 it is possible to set the soft TOP and BOTTOM limits of the
movement of the Roll Down, adjusting its span of motion. Channel 5 is likewise used
for resetting the Roll Down, when powering up.
On the Roll Down it is possible to adjust the hard TOP and BOTTOM limits and in that
way set the absolute span of motion.
Multiple Roll Downs are easily daisy chained with power in-out and DMX in-Out,
allowing to create advanced and dynamic movements with 100’s of Roll Downs working
together in the same installation.
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Safety functions
The control system ensures that the motor only is powered when:
• The control signal is reliable.
• The position and speed control is on.
• The motor position is calculated after which a PID regulator calculates the
motor speed and distance.
• No overload.
Roll Down should only be operated by an experienced DMX-controlled-lighting-deskoperator. The lighting desk has to be programmed according to the manual, so the Roll
Down will stop when the speed is put to 0 %. It is also possible for the user to stop the
Roll Down by disconnecting it from the main. After power failure the start position of
the Roll Down needs to be reset before the Roll Down can function again.
Manual operation of the Roll Down is only intended for mounting, service, and tests.
Area of use
For indoor use only!
Caution! To reduce the risk of electric shock or injury: use indoors only
Caution! To reduce the risk of electric shock, do not expose to rain: store indoors!
The Roll Down is intended for indoor use only. It is designed for lifting and lowering
material at the weight and speed stated in "Technical specifications" on page 6. Any
other use of the Roll Down may result in a risk of injury of persons or equipment
damage.
Exceeding the load rating may cause failure of the equipment.
Use only the Wahlberg approved mounting connectors to secure the load to the tube.
Failure to mount the load securely can result in a risk of injury of persons or
equipment damage.
Do not modify the Roll Down. For any modification of your Roll Down, 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 Roll Down.
Using for the first time
Important! The Roll Down must be protected from environmental factors such as
physical shocks and vibration during transportation and storage.
Warning! Read “Safety Information” on page 2 before installing, powering,
operating, or servicing the Roll Down. Before applying power to the Roll Down:
−
−
−
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Check the Wahlberg Motion Design website at www.wahlberg.dk for the most recent
documentation and technical information about the Roll Down. Wahlberg user
manual revisions are identified by the revision number in the bottom of each page.
Carefully review the “Safety Instructions” on page 2.
Check that the local AC mains power source is within the Roll Down power voltage
and frequency ranges.
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See “Power cables and power plug” on page 2. Install a Neutrik powerCON TRUE1
NAC3FX-W power input connector on a suitable power cable. If using the power from
a mains power outlet, install a suitable power plug on the power cable.
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Transport
Important! The Roll Down must be protected from environmental factors such as
physical shocks and vibration during transportation.
Before transport, it is important to roll the fabric of the Roll Down up until the hard
TOP limit, and wrap the remaining fabric around the tube. Fix the fabric with a cable
tie or an elastic cord.
Use only the original packaging or flight case for protecting the Roll Down during
transport. Contact Wahlberg for enquiries regarding flight cases or pallet frames.
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Physical installation
Warning! The Roll Down 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 mounting clamp
points upwards. Do not apply power to the Roll Down if it is not securely fastened.
Warning! The supporting surface must be hard and flat. Fasten the Roll Down
securely.
Warning! Use only the supplied rigging clamps.
Fastening the Roll Down to a flat surface
The Roll Down can be fastened to flat surface such as a roof. Check that the surface
can support at least 10 times the weight of all Roll Downs and equipment to be
installed on it.
Mounting the Roll Down on a truss
The Roll Down can be clamped to a truss or similar rigging structure.
To clamp a Roll Down to a truss:
1. Check that the rigging clamps are undamaged and that the rigging structure can
support at least 10 times the combined weight of all Roll Downs and equipment to
be installed on it.
2. Block access under the work area. Working from a stable platform, hang the Roll
Down on the truss with the mounting clamp upwards. Tighten the rigging clamp.
3. Use the supplied 2 slim couplers sitting on the top plate. It is important to use
both slim couplers for mounting because the load is not evenly distributed across
the Roll Down.
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Mounting the tube
The Roll Down comes with either a single tube, or two tubes with a splice that allows a
total length of the tube up to 12 meters.
Single tube:
Using a splice:
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Mounting the fabric
Attention! The fabric must be mounted on the tube in a way to insure that the
fabric never can damage the Roll Down.
Attention! There should be minimum 1 round left on the tube when the fabric is
rolled all the way out if it is mounted with the rail.
Attention! There should be minimum 2 round left on the tube when the fabric is
rolled all the way out if it is mounted with tape.
Mount the fabric in the right position
When mounting the fabric it is important to move the tube to the correct position
before you mount anything.
If you are mounting a 4 meter fabric follow these steps.
1. Move the tube to the TOP position with channel 5.
2. Move the tube at least 4 meters down with channel 6
(6.4 rotations: 400cm/62.8cm per rotation)
3. Mount the fabric on the tube either with the rail or with tape.
4. Now Go back up to the desired top position with channel 5
5. Then set the range for the desired movement with channel 6
Less than 4 meter to ensure 2 rounds of fabric should remaining on the tube.
6. Now the 100% position will be with the fabric rolled all the way up and the 0%
position will be with the fabric rolled all the way out.
Attention! If you do not move the Roll Down, down before mounting the fabric the
hard TOP limit will prevent you from rolling the curtain all the way up.
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Using the mounting rail
The Roll Down has a rail that can be used for mounting the fabric along the entire
length of the tube.
The fabric is mounted by loosening the HEX screws holding the rail in place. When they
are all loose, place the fabric under the rail and tighten the screws again to hold it in
place.
Make sure the fabric is mounted on the correct side of the rail. If it is mounted on the
wrong side it will fold over itself when moving to the TOP limit.
Refer to Appendix 1 on page 37 for additional illustrations.
Using tape
The fabric can also be taped to the tube, using single or double faced tape. This allows
the fabric to be mounted at any angle. If tape is used for securing the fabric 2 rounds
must remain on the tube when it is fully rolled out.
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AC power
Warning! Read “Safety Information” on page 2 before connecting the Roll Down to
AC mains power.
Warning! For protection from electric shock, the Roll Down must be grounded
(earthed). The power distribution circuit must be equipped with a fuse or circuit
breaker and ground-fault (earth-fault) protection.
Warning! Socket outlets or external power switches used to supply the Roll Down
with power must be located near the Roll Down and easily accessible so that the
Roll Down can easily be disconnected from power.
Warning! Check that the voltage range specified on the Roll Down’s serial number
label matches the local AC mains power voltage before applying power to the Roll
Down. Do not apply AC mains power to the Roll Down at any other voltage than
that specified on the Roll Down’s serial number label.
Power cables and power plug
The Roll Down requires a power input cable with a Neutrik powerCON TRUE1 NAC3FXW cable connector for AC mains power input. The cable must meet the requirements
listed under “Protection from electric shock” on page 2.
Wahlberg Motion Design can supply the PowerCON input connector without a cable.
If you install a power plug on the power cable, install a grounding-type (earthed) plug
that is rated 20 A. Follow the plug manufacturer’s instructions. The Neutrik assembly
guide below shows standard wire color-coding schemes and some possible pin
identification schemes; if pins are not clearly identified, or if you have any doubts
about proper installation, consult a qualified electrician.
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Installing a power input connector on a power cable
To install a Neutrik powerCON TRUE1 NAC3FX-W input connector on a power
Cable, follow the original Neutrik instructions as described in Appendix 3 in page 38.
By supplying power to the Roll Down, the display will show a start-up screen sequence
showing the model number
Followed by a screen showing the software version, e.g. SW 503.003 as shown below
Then a description of how to enter the menu
When it changes to the following, the Roll Down is ready to be operated:
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Data link
A DMX 512 data link is required in order to control the Roll Down via DMX. The Roll
Down 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 Roll Down but are available for possible additional data
signals as required by the DMX512-A standard.
The Roll Down is subject to the common limit of 32 devices per daisy-chained link.
Note that if independent control of a Roll Down is required, it must have its own DMX
channels. Roll Downs that are required to behave identically can share the same DMX
channels. To add more Roll Downs or groups of Roll Downs when the above limit is
reached, add a DMX universe and another daisy-chained link.
Tips for reliable data transmission
Use shielded twisted-pair cable designed for RS-485 devices: standard microphone
cable cannot transmit control data reliably over long runs. AWG24 cable is suitable for
runs up to 100 meters (328 ft.).
Never split a DMX line without using an opto-isolated RS-485 splitter/amplifier.
Terminate the link by installing a termination plug in the output socket of the last
winch. The termination plug, which is a male XLR plug with a 120 Ohm, 0.25 Watt
resistor soldered between pins 2 and 3, “soaks up” the control signal so it does not
reflect and cause interference. If a splitter is used, terminate each branch of the link.
Connecting the data link
To connect the Roll Down to data:
1. Connect the DMX data output from the DMX controller to the Roll Down’s male
5-pin XLR DMX input connector (DMX 512 IN).
2. Connect the DMX output of the Roll Down to the DMX input of the next Roll
Down and continue connecting Roll Downs output to input (DMX 512 OUT).
3. Terminate the last Roll Down on the link with a 120 Ohm resistor.
The DMX lamp is the green led, above the display.
− Glows constantly, when the DMX connection is correct.
− Flashes if the DMX signal is missing or wrongly connected.
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Emergency stop switch (Optional)
Warning! By default the emergency stop is NOT enabled!
The Roll Down can be configured with an emergency stop; by default the emergency
stop is not enabled.
The DMX control from a lighting desk should always have a set up so there is a button
that sets the speed of the Roll Down in operation to 0%. Normally lighting desks have a
“blackout” button that sets all signals to 0% and this will also cause the Roll Down to
stop.
If the emergency stop switch is activated the red Error LED will be lit and the screen
display shows: ‘EMERGENCY STOP PRESSED’:
The emergency stop switch is connected to the male 4 pole XLR connector on the Roll
Down. Pin 1 and Pin 4 should be powered with 12-15 volt DC to enable operation of the
Roll Down.
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Pin out:
Connection
Pin 1
GND
Pin 2
Not connected
Pin 3
Not connected
Pin 4
12-15 V DV
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Enable Emergency stop
To enable emergency stop two steps are required.
Step 1: In ‘MENU NAVIGATE’ change ‘E STOP’ from OFF
Refer to section Menu setting on page 21 for guidance on how to navigate the menu.
to ON
Step 2: 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
Orange wire loops pin 3 and 7
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 touch
anything. Some electrical tape will be enough to keep it in place.
Ready to use
When the emergency stop has been enabled both in the menu and in the Roll Down,
the Roll Down connected to power, DMX, and an emergency stop switch, it is ready for
use, and can be controlled from the lighting desk.
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Setup
Warning! Read “Safety Information” on page 2 before installing, powering,
operating, or servicing the Roll Down.
Warning! Only experienced DMX users should operate the Roll Down. Contact
Wahlberg for further information and education on DMX protocol.
Menu setting
Use the push buttons on the display to enter and change menu settings
Use the arrows
&
to go up or down in the menu
Push
to set values.
Push
to go back one level in the menu
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Menu structure
The menu structure is divided into two different areas for safer motor control.
Control mode
The display shows:
Shift to next screen by pushing
and hold for 3 seconds:
P:
W:
D:
S:
Current position (values from 0-50000)
Wanted position (values from 0-50000)
Distance from current to wanted position
(maximum shown value 3500)
Speed (values from 0-100)
The screen shows the TAC value for the current position, wanted position, distance
and speed.
E.g. the Roll Down is moving with 100% speed from current position with TAC value
10,000 and the wanted position has the TAC value 24,250:
Shift to next screen by pushing
and hold for 3 seconds:
DMX channel
1
DMX channel
2
DMX channel
3
DMX channel
4
DMX channel
5
DMX channel
6
DMX channel
7 (not used)
DMX channel
8 (not used)
The screen shows the DMX channel values, if e.g. DMX channel 1 is set to 100% and DMX
channel 3 is set to 100%, the screen will show:
To shift back to the previous screens push
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and hold for 3 seconds.
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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 MAN UP/DWN menu though.
Menu mode change
MENU - NAVIGATE:
The top line of the display is showing:
Push both buttons
&
and hold them for 3 seconds.
Now the top line of the display should show:
MENU - DMX CONTROL:
Go back to the starting position and activate DMX control
The top line of the display is showing:
Push both buttons
&
and hold them for 3 seconds.
Now the top line of the display is showing:
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Navigate the menu
The top line of the display is showing:
Push the arrows
or
to go up or down in the menu choices.
The bottom line of the display is showing:
Adjusting menu parameters
The display shows:
Push
to change the DMX ADDR value.
The display shows:
Use the arrows
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or
to adjust the DMX ADDR.
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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.
Adjustable parameters
Menu
MAN SPEED
MAN UP/DWN
DMX ADDR
TAC RANGE
SPEED MAX
SP MIN UP
SP MIN DWN
E STOP
REVERSE DIR
Description
Speed for manual driving
Run the motor manual from the menu
DMX start address
Tacho range
Maximum speed
Minimum speed UP
Minimum speed DWN
Enable/disable emergency stop
Enable/disable reverse direction
Range
Default
200 – 2500
800
MOTOR UP / MOTOR DOWN
1-506
1
1-50,000
N/A
500-3,500
3,500
50-1,000
200
50-1,000
200
ON/OFF
OFF
ON/OFF
OFF
MAN SPEED and MAN UP/DWN are used for manual control of the motor.
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Detailed explanation of parameters
MAN SPEED
Speed for manual driving
MAN SPEED sets the speed for manual driving the motor
Range
200-2,500
MAN UP/DWN
Manually driving the motor
MAN UP/DWN is used for manual control of the motor.
Pressing the UP button, makes the fabric run up. Pressing the DOWN button, makes the
fabric run down, unless the limit switch or slack detection is activated.
The Roll Down will stop if the Emergency Switch is activated.
DMX ADDR
DMX start address
Range
DMX start address defines which DMX address the Roll Down reacts on.
The Roll Down uses 6 DMX channels.
1-506
TAC RANGE
Tacho range
Range
1-50,000
The tacho range is setting the range of the Roll Down from the soft TOP limit to the soft
BOTTOM limit.
The tacho range can be adjusted, using channel 6 for the soft BOTTOM limit. If the same
tac range is required for a range of Roll Downs, use the menu to set the same tac range
easily.
SPEED MAX
Maximum speed
Range
500-3,500
SPEED MAX sets the maximum speed.
If set to 1000, the motor runs at 1000 RPM when DMX speed is set to full. SPEED MAX can
be used to lower the maximum speed, if desired.
SP MIN UP
Minimum speed up
Range
50-1,000
The motor minimum speed, for the up direction.
The motor is allowed to run at different minimum speeds 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
50-1,000
The motor minimum speed, for the down direction.
The motor is allowed to run at different minimum speeds 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 Roll Down. See
section on how to change the wire setting for more details.
REVERSE DIR
Enable/disable reverse direction
Range
ON / OFF
This enables/disables the reverse direction in the software. This means the way the fabric
rolls on the tube is reversed. So instead of rolling over the front of the tube, it rolls down
from the back.
When this is enabled, the hard limits are also switched so the one that was DOWN
becomes UP, and vice versa.
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 Roll Down must be
assigned its own control channels.
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The DMX address is configured in the menu as described in the section above. The
selected DMX address states from which channels, on the lighting desk, the Roll Down
is controlled. The DMX address can be selected from 1 – 506. The Roll Down uses 6×
DMX channels.
DMX channel overview
DMX
channel Function
1
Position
rough
Description
This channel controls the position of the Roll Down, with the speed (DMX channel
3).
This rough position works together with the fine position (DMX channel 2).
The rough position and the fine position are multiplied in to a 16 bit channel. The
rough position is the MSB.
2
Position fine
This channel controls the position of the Roll Down, with the speed set on DMX
channel 3.
This fine position works together with the rough position (DMX channel 1).
The fine position and the rough position are multiplied in to a 16 bit channel. The
fine position is the LSB.
3
Speed
This channel controls the speed and defines the max lifting/lowering speed of the
Roll Down.
This channel also works as a main brake; the motor does not run unless the
channel is set above 0%.
4
Motor enable
Channel 4 is used as a 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.
All other values will save the current position before a power down. If channel 4 is
between 50-55% when powering up, the motor will not run.
5
Setting the
soft TOP limit
Channel 5 is used to move the fabric up. When channel 5 is set ≥ 10% the Roll
Down will move up until it reaches the hard TOP limit. 10 – 100% makes the motor
run up, at variable speed. (10% = low speed – 100% = full speed).
Setting DMX channel 5 to 0 resets the soft TOP limit, to the current position.
There is a 3s delay on this channel to reduce risk of accidentally resetting the soft
TOP limit.
6
Setting the
soft BOTTOM
limit
Channel 6 is used to move the fabric down and setting the soft BOTTOM limit.
When channel 6 is set ≥ 10% the Roll Down will move down, until it reaches the
hard BOTTOM limit. 10 – 100% makes the motor run down, at variable speed. (10%
= low speed – 100% = full speed).
The position is reset and a new TAC RANGE is calculated. The new range is the
tacho pulses, between the soft TOP limit set by channel 5 and soft BOTTOM limit
set by channel 6.
The Roll Down should be reset to the soft TOP limit with channel 5, before the
range is set with channel 6.
There is a 3s delay on this channel to reduce risk of accidentally setting a new tac
range.
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Adjusting hard limit switches
Warning! There must be at least 1 rounds left on the tube when the Roll Down 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 Roll Down itself, this will damage the Roll Down.
The hard limit switch determines the maximum and minimum travel distance of the
Roll Down. The hard limits are adjusted by rotating the white levers using the screws
for hard TOP and BOTTOM limit.
When the hard TOP limit is activated, the display will show:
When the hard BOTTOM limit is activated, the display will show:
The hard limit switch makes a ‘click-sound’ when the limit switch is pressed or
released.
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Adjusting procedure
1. Put the Roll Down in manual mode while adjusting the limits.
2. Localise the hard limit switch box, the black box just in front of the fan.
3.
4.
5.
6.
7.
8.
Loosen the two screws holding the lid.
Loosen the middle screw.
Hard BOTTOM limit is adjusted by turning the screw with a 1 next to it.
The hard TOP limit is adjusted by turning the screw with a 2 next to it.
When adjustments are done tighten the middle screw again.
Mount the lid with the two screws again.
The hard limits are factory pre-set to have a travel length of 15 m (can be extended to
18 m).
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Normal Operation
Temperatures
If the surface temperature of the Roll Down exceeds 90°C (194°F) there is a risk of
damaging the Roll Down.
Duty cycle
The Roll Down 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. The duty cycle is
commonly expressed as a percentage or a ratio. It can be described as the period of
time it takes for a system to complete an on-and-off cycle.
Thus, a 10% duty cycle means the system is on 10% of the time and off 90% of the time.
The "on time" for a 10% duty cycle is normally connected to a cycle length in minutes.
E.g. a max duty cycle of 30% (10 min ON / 23 min OFF), means that the motor may not
be active more than 10 minutes every 33 minutes or after 10 minute of ON the motor
must be OFF for 23 minutes.
Lifting speeds and weight
The load of the Roll Down impacts the minimum speed it can operate at. At heavy
loads the minimum speed up must be increased to a point where the Roll Down can
still move.
If a light load is used with high minimum speeds the Roll Down 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.
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Synchronized movements of multiple Roll Downs
If several Roll Downs are installed to perform synchronized movements the best result
is achieved by using a fading 16 bit position. The Roll Downs have a slight deviation in
performance of the motors, so some motors have a slightly higher maximum speed
than others.
This difference in speed can be solved by running the Roll Downs with fading positions,
like when fading conventional light over time, the position of the Roll Down should be
faded from one position to another over a certain amount of time. In that way the Roll
Downs will follow the fade-curve, and multiple Roll Downs can follow the same fade
curve.
When fading the positions:
1. The speed channel should be set to 100 to gain the highest possible speed.
2. The position channel should be assigned as a 16 bit channel with MSB and LSB.
3. The speed of the fade needs to be slower than the maximum speed, so the
motors have speed enough to follow the fade-curve.
If the fade of the positions is too fast, the Roll Downs will move at the maximum
speed, and you will see the difference in the motor speed.
If the fade is to slow the Roll Downs will move – stop – move – stop, when the position
changes, thus giving a discontinuous movement.
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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.
When the Error LED lights red, there will also be an error description in the display.
Error and error codes:
Error
Roll Down will not start,
display shows nothing.
Possible solution
Check if the Roll Down is connected to mains power.
Check if the fuse in the Roll Down is intact
Roll Down will not start,
DMX lamp is blinking.
The fabric is not wound up
on the tube correctly.
Check DMX signal
Display says “Not in Pos”
Power failure
Manually lower the fabric totally off the tube, while controlling that
the fabric comes out of the Roll Down evenly. Afterwards the fabric is
rolled back onto the tube.
Reset the top position afterwards.
The Roll Down cannot move to its position, this usually occurs when
the load is high. To solve this go into the menu and increase the
Minimum speed up.
The Roll Down will stop at power failure. When the power is reestablished, the Roll Down 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.
When an error occurs, the control system shuts down the connected motor and issues a
corresponding error code. This can be queried, and used to determine the cause of the
error.
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Code
Error message
2
OVERVOLTAGE
Shutdown due to undervoltage in the DC
link.
Shutdown due to overvoltage in the DC link.
4
OVERTEMP. >70C
Shut down due to inverter overheat.
1
UNDERVOLTAGE
Cause
Solution
The input voltage might be too low.
The input voltage might be too high.
The temperature of the power electronics in the frequency inverter is too high.
The cooling is insufficient, for example, ambient temperature too high,
insufficient air circulation, dirty air grate or the fan is defective.
The drive can only be restarted when it has been allowed to cool down.
5
MOTOR OVERTEMP.
Shut down due to motor overheat
This message is issued when the motor thermostat is triggered or the
temperature of the motor PTC is exceeded.
The motor is being insufficiently cooled, for example, due to a defective fan.
The drive can only be restarted when it has been allowed to cool down.
6
INV OVERCURRENT.
Shut down due to inverter overload.
Inverter output current (active current) too high.
Possible cause:
→ The motor load is too high
7
INV OVERCURRENT.
Shut down due to inverter overcurrent.
The momentary output current is permanently exceeding the rated current by
more than 150%.
Possible causes:
→ The motor load is too high
8
INVRTER EEPROM
Malfunction in the inverter memory.
Power cycle the Roll Down. Unplug the power and wait 30 seconds before
applying power again.
9, 64
INVERTER SHORT
This is the switch off function due to a
short-circuit on the frequency inverter
The inverter was heavily overloaded (also short term).
Causes can be for example:
a short-circuit / earth fault in the motor or in the supply leads.
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10
INV NOT ENABLED
Inverter enable signal missing at the control
terminal rail, terminal 3.
The inverter can only be started if an active enabling signal (12-15 V) is applied
to the control terminal rail. If this signal fails during drive operations, the
motor will shut down and coast to a standstill. The shutdown immediately
affects the inverter power section.
This signal is provided by an orange wire connected to the number 3 connection
on the terminal rail in the Roll Down. If this wire is not connected this error
will occur.
11
INV SER TIME OUT
Shutdown when
interface).
telegrams
fail
(serial
Power cycle the Roll Down.
Unplug the power and wait 30 seconds before applying power again.
255
INV SER TIME OUT
Timer reset of the watchdog.
Power cycle the Roll Down.
Unplug the power and wait 30 seconds before applying power again.
12
INVERTER TIMING
Internal timing error
Power cycle the Roll Down.
Unplug the power and wait 30 seconds before applying power again.
13
INVERTER SYSTEM
System error
Power cycle the Roll Down.
Unplug the power and wait 30 seconds before applying power again.
14
INV START DIRECT
Start attempt with direction error
Power cycle the Roll Down.
Unplug the power and wait 30 seconds before applying power again.
15
INV PROGRAM CRC
Program memory CRC error
Power cycle the Roll Down.
Unplug the power and wait 30 seconds before applying power again.
16
INV NOT ENABLED
Inverter enabling signal error
The inverter can only be started if an active enabling signal (12-15 V) is applied
to the control terminal rail. If this signal fails during drive operations, the
motor will shut down and coast to a standstill. The shutdown immediately
affects the inverter power section.
This signal is provided by an orange wire connected to the number 3 connection
on the terminal rail in the Roll Down. If this wire is not connected this error
will occur.
17, 250
INV WATCHDOG RST
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Power cycle the Roll Down. Unplug the power and wait 30 seconds before
applying power again.
Date: 2017-10-30
Service and maintenance
Warning! Read “Safety Information” on page 2 before servicing the Roll Down.
Warning! Disconnect the Roll Down from AC mains power and allow cooling down
for at least 10 minutes before handling.
Warning! Refer any service operation not described in this user manual to a
qualified service technician.
Attention! Interval of inspections should be determined according to the frequency
of use and the working scenario of the Roll Down.
Attention! Signs of malfunction or poor operation should always lead to an
inspection of the Roll Down, and the Roll Down should be taken out of operation
until the error is eliminated.
Parts
Only parts ordered at or approved by Wahlberg should be used in the Roll Down to
ensure product function and stability. Contact Wahlberg to inquire about spare parts.
On-site service
On-site service and maintenance can be provided by the Wahlberg Motion Design,
giving owners access to Wahlberg Motion Design’s expertise and product knowledge in
a partnership that will ensure the highest level of performance throughout the
product’s lifetime. Please contact Wahlberg Motion Design for details.
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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 Roll Down showing the date of
the inspection, the basis of the inspection and the name of the inspector.
Before every use and weekly
Every time when rigging the Roll Down, before running the Roll Down – and at least
every week when the Roll Down is in use:
− Check that the Roll Down is safely and correctly installed/mounted.
− Inspect the entire length of the tube for bends, damage, wear, and abuse.
− Inspect the fabric attachment for damage, wear, or abuse.
− Check that the fabric winds neatly around the tube
− Check that the fabric weighs maximum 35 kg.
− Check all safety devices (limit switches, and emergency stop)
− Check that the Roll Down’s LEDs are visible from the operating station.
− Make sure that the operator has visual confirmation of all possible movements
of the Roll Down at all time.
Monthly
At regular intervals – but at least every month when the Roll Down is in use:
− Check the mounting clamps for damages and proper fastening.
− Change damaged parts according to this manual.
Yearly
The Roll Down has to be inspected by a specialist every 12 months.
Every 48 months
The Roll Down should be inspected by an authorised expert every 48 months.
Checklist
Use the checklist accordingly; before each use, each month etc.
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Check
Type
Installed / mounted correct
Inspection
Load and LEDs visible for the operator
Inspection
Entire tube length OK
Inspection
Emergency stop
Functional test
Fabric is winds neatly around the tube
Inspection
Fabric attachment
Inspection
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Appendix 1
Roll Down (249)
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Appendix 2
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Appendix 3
Block diagram of the control system of the Roll Down.
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Roll Down - Cheat Sheet
DMX channels
1
2
3
4
5
6
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
Setting soft TOP limit
Setting soft BOTTOM limit
How to get started
1.
2.
3.
4.
Place / Rig the Roll Down in something high with minimum 2-3 meter clearance below.
Connect the Roll Down to 230VAC – The Roll Down turns on and the display shows the start-up message.
Connect emergency switch (if enabled) – make sure the error LED no longer is glowing red.
Set the DMX start address to 1 and apply DMX from a lighting desk, preferably with manual faders.
Make sure that the 6 channels are patched from DMX channel 1 to 6. Pull all channels on to 0%
5. Set DMX channel 4 between 50% and 55% - the motor is now enabled
6. Set DMX channel 5 to 30% - After 3s the Roll Down moves towards its hard TOP limit. To stop the Roll
Down, set DMX channel 5 to 0%. Stop when the desired or at the hard TOP limit. The reached position is
now the soft TOP limit.
7. Set DMX channel 6 to 50% - The Roll Down moves towards its hard BOTTOM limit. To stop the Roll Down,
set DMX channel 6 to 0%. Stop when desired or at the hard BOTTOM limit. The reached position is the soft
BOTTOM limit, and hence the travel range has now been set: from the soft TOP limit to the soft BOTTOM
limit.
8. Set DMX channel 1 to 100% and DMX channel 3 to 20% - The Roll Down moves with 20% speed to the
100% position.
9. Set DMX channel 1 to 90% and DMX channel 3 to 50% - The Roll Down moves with 50% speed to the 90%
position.
Emergency stop switch (Only when emergency stop is enabled)
The emergency stop switch is connected to the female 4 pin XLR connector.
Pin 1 and Pin 2 should be connected to each other; otherwise the motor will not run.
Pin out:
Pin 1
Pin 2
Pin 3
Pin 4
GND
NC
NC
12-15 volt DC
Emergency stop input
Emergency stop input
Before each use
−
−
−
−
−
Inspection points!
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Inspect the entire length of the tube for bends, damage,
wear, corrosion, and abuse.
Inspect the fabric attachment for damage, wear, or abuse.
Check that the fabric weighs maximum 35 kg.
Check all safety devices (limit switches, and emergency stop)
Make sure that the operator has visual confirmation of all
possible movements of the Roll Down at all time.
Warning!
Do not use the Roll Down if any damage or error is found!
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