1. Introduction
This manual provides comprehensive instructions for the safe installation, operation, and maintenance of the Lewmar 12V Dual Relay, Model 68000939. This compact and water-resistant unit is specifically designed to efficiently manage dual circuits for marine windlass systems, ensuring reliable high-current switching in confined spaces.
The Lewmar 12V Dual Relay is compatible with various Lewmar windlass models, including VX1, VX1L, HX1, Pro-series 700, Pro-series 1000, and Pro-Sport windlasses. Its robust construction ensures professional performance and adherence to strict quality standards.
1.1 Safety Information
- Always disconnect the power supply from the battery before attempting any installation, maintenance, or troubleshooting. Failure to do so can result in serious injury or damage to equipment.
- Installation should be performed by a qualified marine electrician or technician familiar with marine electrical systems.
- Ensure all wiring connections are secure, properly insulated, and free from corrosion. Loose connections can lead to overheating and fire hazards.
- Use appropriate personal protective equipment (PPE) during installation and maintenance.
- Do not operate the relay if it appears damaged or has been submerged in water.
2. Product Overview
Figure 2.1: Lewmar 12V Dual Relay (Model 68000939)
This image displays the Lewmar 12V Dual Relay, a compact black electrical component with two large threaded terminals on top for high-current connections and smaller spade terminals on the side for control wiring. A red sealing ring is visible around the main body, indicating its water-resistant design. Two mounting screws are visible at the bottom of the unit, along with a metal mounting bracket.
Key Features:
- Compact Design: Optimized for installation in tight marine environments.
- Dual Functionality: Manages two devices simultaneously, enhancing system efficiency.
- High-Current Switching: Designed for reliable operation with high electrical loads, typical of windlass motors.
- Water-Resistant: Built to withstand marine conditions.
- Compatibility: Seamless integration with various Lewmar windlass models (VX1, VX1L, HX1, Pro-series 700, Pro-series 1000, Pro-Sport).
3. Setup and Installation
Proper installation is crucial for the safe and efficient operation of your Lewmar 12V Dual Relay. Refer to your specific windlass manual for detailed wiring diagrams and recommendations.
3.1 Mounting Location
- Choose a dry, protected location, ideally within a locker or engine compartment, away from direct exposure to water spray or extreme heat.
- Mount the relay as close as possible to the windlass motor and the battery bank to minimize voltage drop in the heavy gauge power cables.
- Ensure adequate ventilation around the unit.
- Secure the relay firmly using appropriate marine-grade fasteners through the mounting holes provided on the bracket.
3.2 Wiring Connections
Before making any connections, ensure the main battery switch is OFF and the battery is disconnected.
- Identify Terminals: The relay typically has two large terminals for the main power circuit (battery and motor) and several smaller spade terminals for the low-current control circuit (from the windlass switch). Consult the diagram provided with your windlass or the relay for specific terminal identification.
- Battery Connections: Connect heavy gauge positive (+) and negative (-) cables from your battery bank to the designated main power terminals on the relay. Ensure the cable size is appropriate for the current draw of your windlass and the length of the run.
- Windlass Motor Connections: Connect heavy gauge cables from the relay's output terminals to the corresponding terminals on your windlass motor.
- Control Switch Connections: Connect the low-current control wires from your windlass control switch (e.g., foot switches, helm switch) to the smaller spade terminals on the relay. These wires typically activate the "Up" and "Down" functions of the windlass.
- Grounding: Ensure proper grounding of the relay and the entire windlass system to the boat's common ground point.
- Secure All Connections: Use marine-grade crimp connectors and ensure all nuts and screws are tightened securely. Apply dielectric grease or a corrosion inhibitor to all electrical connections to prevent oxidation.
After all connections are made, double-check your wiring against the diagram before reconnecting the battery and restoring power.
4. Operating Instructions
The Lewmar 12V Dual Relay functions as an integral part of your windlass control system. It is not a directly user-operated device but rather an automatic switch that responds to commands from your windlass control switches.
- When you activate a windlass control switch (e.g., pressing an "Up" foot switch or a "Down" button at the helm), a low-current signal is sent to the relay.
- The relay then closes its internal contacts, allowing the high-current power from the battery to flow directly to the windlass motor, causing it to operate.
- When the control switch is released, the relay opens its contacts, cutting power to the windlass motor.
Always ensure the anchor is clear of obstructions and the chain/rode is properly stowed before operating the windlass. Operate the windlass in short bursts to prevent overheating of the motor and relay.
5. Maintenance
Regular inspection and basic maintenance will ensure the longevity and reliable performance of your Lewmar 12V Dual Relay.
- Visual Inspection: Periodically inspect the relay and all associated wiring for any signs of corrosion, fraying, cracks, or loose connections. Pay close attention to the main power terminals.
- Cleanliness: Keep the exterior of the relay clean and free from dirt, salt residue, and moisture. Use a damp cloth for cleaning; do not use harsh chemicals or abrasive materials.
- Connection Integrity: Annually, or if intermittent operation is observed, check the tightness of all electrical connections. Do not overtighten.
- Environmental Protection: Ensure the relay's mounting location remains dry and protected from excessive moisture or direct water ingress.
The Lewmar 12V Dual Relay contains no user-serviceable parts inside. Do not attempt to open or repair the unit. If the unit is faulty, it should be replaced.
6. Troubleshooting
If you experience issues with your windlass system that you suspect are related to the relay, follow these troubleshooting steps:
| Symptom | Possible Cause | Solution |
|---|---|---|
| Windlass does not operate, relay does not click. |
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| Windlass operates intermittently or weakly. |
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| Relay clicks but windlass does not operate. |
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If you are unable to resolve the issue after following these steps, it is recommended to consult a qualified marine electrician or contact Lewmar customer support.
7. Specifications
| Attribute | Detail |
|---|---|
| Brand | Lewmar |
| Model Number | 68000939 |
| Voltage | 12V DC |
| Material Type | Plastic |
| Power Source | Electric |
| Features | Water-resistant |
| Approx. Package Dimensions (L x W x H) | 9.19 x 8.61 x 6.4 cm (3.62 x 3.39 x 2.52 inches) |
| Approx. Package Weight | 317.51 g (0.7 lbs) |
| Compatibility | Lewmar VX1, VX1L, HX1, Pro-series 700, Pro-series 1000, Pro-Sport windlasses |
| UPC | 787392649061, 743683329098 |
| GTIN | 00743683329098 |
8. Warranty and Support
For specific warranty terms and conditions related to your Lewmar 12V Dual Relay, please refer to the documentation provided at the time of purchase or visit the official Lewmar website. Warranty coverage typically varies by region and product.
If you require technical assistance, have questions about installation, or need to report a product issue, please contact Lewmar customer support. Contact information can usually be found on the Lewmar official website or through your authorized dealer.
Lewmar is a proud member of the Lippert family, a leading manufacturer and supplier of advanced products for the marine and other industries, committed to customer satisfaction.
