Andersen Stainless Steel Winches® | Ronstan Sailboat Hardware
User Manual for RONSTAN models including: 50ST Compact Motor Below Deck Electric Winch, 50ST, Compact Motor Below Deck Electric Winch, Motor Below Deck Electric Winch, Below Deck Electric Winch, Deck Electric Winch, Electric Winch, Winch
Support Manuals & Service Tips | Andersen Winches | Ronstan Sailboat Hardware
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DocumentDocumentPRODUCT MANUAL Compact MotorTM Below Deck Electric Winch 46/50ST FOR USE WITH: Compact MotorTM Electric Winches RA2046014100 RA2050014100 RA2046014200 RA2050014200 Compact MotorTM Conversion Kits RA2046214100 RA2050214100 RA2046214200 RA2050214200 Winch Versions: 46ST (V.4.0) 50ST (V.1.0) Your Winch Version No. ____________________________________ Your Motor Serial No. ________________________________________ 710203 Rev.2 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Contents PAGE 2 3 4 5 6-10 11 12 13-16 17 18-19 20 21 22 Functionality Safety notices Exploded view of assembly and items included Parts list Installation instructions motor and push button Important notes - electrical installation Wiring diagram Electrical installation Winch installation Troubleshooting LED status codes / diagnostics Service and maintenance Contact and warranty information ANDERSEN Stainless Steel Winches® Your Andersen winch is made with the care and craftsmanship that come from more than sixty years of experience. Andersen winches are built to last, to retain their exceptional finish and to deliver season after season of reliable performance and sailing pleasure to their owners through the years. Compact MotorTM functionality The Andersen Compact MotorTM is a brushless DC motor, carefully matched to a low profile planetary gearbox, which requires less space for installation and draws considerably less current than traditional motor/gearbox configurations. Simplified electrical installation requires no external control box. The Compact MotorTM includes a dedicated circuit breaker with integral controller and two illuminated "intelligent" push buttons which regulate speed and power in the low and high speed ranges of operation, in proportion to the pressure applied. Manual operation is possible at any time using a normal winch handle. Monitoring and protection The integrated controller will cause the motor to stop without tripping the circuit breaker if one of the following conditions is detected: · Maximum pulling load exceeded. The motor will cut out if the pre-set maximum pulling load of the winch for electrical operation is exceeded. Operation can resume within a few seconds when the load returns below the limit. · Overheating. The motor will cut out if the temperature of the motor circuit reaches 60°C (140°F). Operation can resume when the temperature returns to normal. · Maximum continuous run time exceeded. The motor will cut out after running continuously for 4 minutes and 15 seconds. Operation can resume after releasing the push button to pause operation for at least 30 seconds. In these cases, the illuminated push button will flash, indicating that the controller will reset automatically when operating conditions return to normal. PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM SAFETY NOTICES Read All Safety Notices and Product Manuals Do not install or operate this winch before reading and fully understanding the contents of this Safety Notice Sheet and the Product Manual. Stay Alert When Operating Andersen winches are very powerful and have the potential to cause significant damage and/or serious injury if used improperly or without due caution and vigilance. Operators Must be Trained Help prevent significant damage and/or serious injury by ensuring any person operating a winch has a thorough understanding of its proper operation and is aware of the potential hazards involved. As a minimum, all winch operators must read and understand this Safety Notice Sheet and the Product Manual. Particular attention is drawn to the following points: · Children and others not qualified to operate an electric winch must be kept at a safe distance from the winch and any rigging or fittings that are under load. · Long hair and/or loose clothing must be tied back to avoid being caught in the winch. · In the event of a rope override or other fault, stop the winch and turn off power before attempting to resolve the problem. Avoid Accidental Operation Always turn off power to the winch at the circuit breaker and remove winch handles when not in use to help avoid unsupervised or unintentional operation. Failure to do so could result in significant damage and/or serious injury. Maintenance Turn off power to the winch before performing any maintenance or service tasks. Failure to do so could result in significant damage and/or serious injury. Lifting Operations The winch must not be operated with the rope in the self tailer when used in any kind of lifting operation. Any lifting operations should be conducted by two persons in order to maintain constant visual contact with the object being lifted. Furthermore the self tailer must not be used as a cleat for a rope used to lift or suspend any object. The rope must be secured properly by tying off, or leading to a suitable fitting such as a cleat or bollard. Failure to observe these precautions could result in serious injury or death. DO NOT DISCARD 2 3 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Exploded View 46/50ST Below Deck Compact MotorTM 12V/24V 2 A8 3 4 A1 A4 5 A2 A5 1 A11 A6 Mounting Dimension Template Andersen Winches E1 & Compact MotorTM Below Deck Electric Self Tailing Winches, Size 58 & 62 Scale Page size Product No. 1:1 A3 RA2058011300 RA2062011300 RA2058011400 RA2062011400 RA2058014100 RA2062014100 RA2058014200 RA2062014200 This template document has been created at 1:1 scale. It is critical that IMPORTANT it is printed at 1:1 scale. Check any printed/reproduced copies match the dimensions indicated at 1:1 scale prior to use. SELF-TAILING ARM CAN BE REPOSITIONED IN 45 DEGREE INCREMENTS AFTER INSTALLATION 230mm 9 1/16" WINCH BASE 60° TYP 39.74mm 1 9/16" 29.00mm 1 1/8" 70mm 2 3/4" CUTOUT FOR ELECTRIC MOTOR 10.50mm [13/32"] x 6 EQUALLY SPACED ON A 200mm [7 7/8"] P.C.D. ART No: RD100214 Mounting Dimension Template Part No. RD100214 - Rev.2 A3 Mounting Dimension Template Andersen WinchesTM Push Button - E1, Two Speed & Three Speed Electric Winches Scale 1:1 Page size A4 (210mmW x 297mmH) Product No's RA582000, RA582010, RA582020 2mm (1/16'') 3 HOLES Ø3mm (1/8'') TYP HOLE Ø5mm (3/16'') for breather tube 50mm (1 15/16'') HOLE Ø25mm (1'') OFFSET 2mm from centre of switch 37mm (1 7/16'') Cover in open position 12mm (1/2'') 20mm (3/4'') 9mm (3/8'') 50mm (1 15/16'') 25mm (1'') HOLE Ø19mm (3/4'') ON CENTRE 50mm (1 15/16'') Method A Blue shaded areas of template Drill a Ø19mm (3/4") hole at the centre of the push button location, and a Ø5mm (3/16") hole immediately beside for the breather tube (as indicated on the template). Method B Red shaded areas of template Drill a Ø25mm (1") hole at a 2mm (1/16") offset to the centre of the push button location (as indicated on the template). RON-MDT/PBE1-Rev.2. 01-05-18 A3 4 A10 A7 A13 A12 PRODUCT MANUAL Compact MotorTM Below Deck Electric Winch 46/50ST FOR USE WITH: Compact MotorTM Electric Winches RA2046014100 RA2050014100 RA2046014200 RA2050014200 Compact MotorTM Conversion Kits RA2046214100 RA2050214100 RA2046214200 RA2050214200 Winch Versions: 46ST (V.4.0) 50ST (V.1.0) Your Winch Version No. ____________________________________ Your Motor Serial No. ________________________________________ A9 710203-Rev.1 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Parts List ITEM NO. QTY 1 1 1 1 2 1 3 1 4 1 5 1 A1 1 A2 1 A3 1 A3 1 A4 1 A5 1 A6 1 A7 1 A8 3 A9 1 A10 2 A11 1 A12 1 A13 1 DESCRIPTION Motor Compact BD, 12V for 46ST, 50ST Motor Compact BD, 24V for 46ST, 50ST Circlip Gearwheel Grub screw Clamping ring Push button with plastic cover Push button gasket Drilling template for 46ST, 50ST Compact BD Drilling template for RA866000 push button Hex keys, metric Eye bolt M6 Pin spanner, Ø5mm pins Push button labels Screw M4x20mm, self tapping Product Manual Control cable, 1000mm (39") Circuit breaker with integral controller Drain tube Compact BD Seal Service Kit OPTIONAL ACCESSORIES: Push button, stainless steel cover Push button, stainless steel cover with hole Control cable extension, 1000mm (39") Control cable extension, 4000mm (157") Drive Shaft & Housing Extension Kits PART NO. RD825300 RD825500 RD829670 584601 DIN916-A4-M5x8 584510 RA866000 735050 RD100896 RD738000 RD100029 RD100025 RD877610 877750 RD877408 RA710022 RA866010 RA866020 RD877610 RD877611 Contact Dealer 5 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Required for installation · Hex keys, metric (included) · Pin spanner, 5mm pins (included) · Cross head screwdrivers · Drill bit Ø8.5mm for M8 mounting bolts (or drill bit 11/32" for 5/16" bolts) · Drill bit Ø3mm (1/8'') · Ø70mm (2 3/4'') hole saw, or jigsaw · Ø25mm (1'') hole saw · 5x M8 (5/16'') CSK mounting bolts and locking nuts (length as required for deck thickness) · 5x M8 (5/16") ID large washers, or backing plate to match drilling template · Spanners: 13mm for motor and circuit breaker terminals, 10mm (1/2") for winch mounting nuts · Sealant / bedding compound · Wire crimping tool/pliers · Marine grade electrical power cables with lugs to suit your battery terminals and the M8 motor and circuit breaker terminals Before Installation Before installation, record the version number of your winch and the serial number of your motor in the space provided on the front cover of this manual for future reference. These details can be found as shown below. Winch production year and month [YY-MM] followed by version number are stamped on winch base between the mounting bolt holes. PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Installation Instructions STEP 1 Determine the position of the winch and motor unit 1.1 Magnetic fields in the motor may affect compasses even when the motor is not in use. Install the motor at least 1m (3ft) away from any compass, and always have your compass recalibrated after installation. 1.2 The winch should be positioned with the recommended line entry angle of 3-8° from horizontal. 1.3 Refer to the Winch Data Sheet for your winch model for clearance/space requirements for the motor unit below deck. You may choose to drill a small pilot hole to indicate the position of the centre of the drive shaft, to assist with this. 1.4 Note the location of the drain port in the base of the motor. If the mounting surface is not horizontal due to deck camber or other factors, plan the installation such that the drain port is situated at the lowest point in relation to the slope of the mounting surface. The drain tube [A12] will be attached to this port to allow any moisture from condensation to escape and drain to the bilge. 3-8 degrees Recommended line entry angle Serial number engraved on bottom of motor. 6 7 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM STEP 2 Install the deck plate 2.1 Refer to the product manual for your 46 or 50ST winch. Disassemble the winch and base cover to access the deck plate for installation. Remove the plug in the base plate to expose the octagonal hole where the motor drive unit will be connected. 2.2 The drilling template [A3] can be used to identify the locations on deck for the mounting holes and deck cut-outs. The self-tailing arm of the winch can be adjusted after installation into one of eight different positions as indicated on the drilling template. 2.3 Use the drilling template as a guide for preparing the deck. Ensure that the mounting surface is flat and there is adequate space and clearance on deck for the winch base and below deck for the motor. With the drilling template in the desired orientation, drill or cut the Ø70mm (2 3/4'') hole for the motor drive shaft housing. 2.4 Drill the Ø8.5mm holes for the M8 deck plate mounting bolts (11/32" holes for 5/16" bolts). 2.5 Clean any wood or fibreglass splinters from the holes, and clean the deck thoroughly to ensure deck sealant can adhere properly. 2.6 Apply sealant to the deck where the deck plate will be fixed. For aluminium boats use a galvanic isolating ring/gasket. 2.7 Fit the deck plate to the deck using appropriate length M8 or 5/16" countersunk head bolts, large washers or backing plate, and locking nuts. Base plate plug removal Typical self-tailing arm positions Drilling template use 8 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM STEP 3 Fit the motor unit to the deck plate Correct alignment of the motor during assembly is essential. Improper alignment can cause excessive noise and vibration and lead to premature wear of bearings and gears. For best results the following steps should be carried out by two persons. 3.1 Refer to the exploded diagram and remove the circlip [2], gearwheel [3] to expose the clamping ring [5]. 3.2 Back out the locking grub screw [4] and use the pin spanner [A6] to remove the clamping ring from the top of the drive shaft housing, taking care that the O-ring underneath remains in place. 3.3 Screw the M6 eye bolt [A5] into the threaded hole in the top of the drive shaft. Attach a strong rope or use a lifting device to raise the motor unit into position so that the drive shaft protrudes through the large octagonal hole in the deck plate. 3.4 Align the motor unit so that the protruding octagonal detail at the top of the drive shaft housing mates snugly with the octagonal recess in the deck plate, for a uniform flush fit. 2. Eye bolt 4. Grub screw 3. Clamping ring Drive shaft O-ring Deck plate Deck plate Drive shaft housing Octagonal detail on drive shaft housing mates with recess in deck plate. 3.5 Fit and securely tighten the clamping ring using the pin spanner, then insert and tighten the locking grub screw. Watertight assembly is ensured by the O-ring under the deck plate; no additional sealant is required. 5. 3.6 After securing the clamping ring, reassemble the gearwheel and circlip on the shaft. 3.7 Refer to the diagrams below to check for correct clearance and alignment. Incorrect mating of drive shaft housing top flange with underside of winch base Correct mating of drive shaft housing top flange with underside of winch base Grub Screw Clamping Ring Deck Plate Clamping ring not parallel to deck plate Grub Screw Clamping Ring Deck Plate 90° Motor flange Grub screw protruding too far Non-aligned hole in deck preventing correct motor alignment Inadequate underdeck clearance preventing correct motor alignment Locking grub screw 9 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM STEP 4 Fit drain tube 4.1 Remove the plastic plug from the drain port fitting and push the drain tube [A12] into the fitting until it stops. Lead the drain tube below deck to a low point in the boat where it can drain to the bilge, then cut off any excess length. At most there should only ever be a drop or two of water from condensation that will pass through the tube. Drain port fitting Plastic plug removed from drain port STEP 5 Install push button The push button requires 50mm (2") clearance depth below the mounting surface. It is supplied with a short 190mm (7 1/2") long cable lead; this is connected below deck to the 1000mm (39") long control cable [A10] and then to the short cable leads from the motor. Extension cables are available and may be ordered separately if necessary. 5.1 Select the desired location. For safety reasons it is recommended that the push button [A1] is located in close proximity to the winch, preferably within reach. 5.2 Determine the preferred orientation of the hinged cover (on vertical surfaces it should open upwards). Then using the drilling template or the rubber gasket [A2] as a guide, drill a Ø25mm (1") hole. 5.3 Drill a Ø3mm (1/8") hole in each of the three mounting screw locations. 5.4 Fit gasket and push button in place. Secure the push button unit with the 3x M4x20mm self tapping screws [A8], using a small amount of sealant at each hole. 5.5 Ensure that the breather channel on the side of the through-deck tube of the push button is clear and free of dirt or sealant. Mounting screws Hinged cover Push button Rubber gasket Push button installation 10 Breather channel Drilling template PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Important Notes - Electrical Installation Incorrect electrical installation will result in permanent damage to the motor and invalidation of the warranty. Warning! The positive cable (+RED) must be connected to the positive (+RED) terminal of the motor. Incorrect polarity will cause permanent damage to the motor. Battery compatibility Andersen Compact MotorsTM produced from 2011 onward are compatible with wet cell, AGM and gel batteries. Furthermore they may be used with Lithium-ion batteries supplied by Super BTM, MasterVolt® and Victron®. These batteries have been tested for compatibility and have built-in protection to prevent damage to the motor, battery and other elements of the system. Other brands of Lithium-ion batteries are NOT approved for use with Andersen Compact MotorsTM. Super BTM is a trademark of Super B International B.V. MasterVolt® is a registered trademark of MasterVolt International B.V. Victron® is a registered trademark of Victron Energy B.V. Operation The Andersen Compact MotorTM electric winch uses a brushless DC motor. Brushless DC motors draw current from the battery when operating, and can send current back to the battery when spinning down unloaded. Avoid operating the winch using the motor at high speed with no load on the drum, as spinning down an unloaded motor from high speed can stress the motor and battery and could result in reduced service life or damage to the motor, battery or other elements of the system. Further Considerations · Always disconnect power when not in use, and before performing any service or maintenance work on an electric winch. · Use only an original Andersen control cable to connect the push button to the Compact MotorTM. Extension cables may be ordered separately. · Use only the Andersen circuit breaker supplied with your Compact MotorTM; do not use it with other devices. · Supply power to the motor only from the battery; never from an external power supply. · Refer to the wiring diagram and cable size recommendations in the Andersen Winch Data Sheet for the model and voltage corresponding to your Andersen Compact MotorTM Electric Winch. · Never use solvents for cleaning control cables or wires use only alcohol for this purpose. Failure to observe these notices will invalidate the warranty. 11 Wiring Diagram PUSH BUTTON [A1] CONTROL CABLE [A10] PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM WARNING The positive cable (+RED) must be connected to positive terminal of the motor. INCORRECT POLARITY WILL CAUSE PERMANENT DAMAGE TO THE MOTOR AND INVALIDATE THE WARRANTY! PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Motor Detail Positive (+) Terminal RED M8 Thread Negative (-) Terminal BLACK M8 Thread Drain port fitting with drain tube WINCH MOTOR [1] THERMAL SENSOR WIRES BATTERY CIRCUIT BREAKER CONTROLLER [A11] Thermal sensor wires Control cable (connection to push button) 12 13 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM STEP 6 Prepare the power cables 6.1 Choose the shortest and most direct route possible for the cables, in order to minimise voltage drop between the battery and the motor. 6.2 Measure the distance from the battery to the motor, and back again via the circuit breaker, to determine the necessary total cable length. 6.3 Consult the table in the Winch Data Sheet for the model and voltage corresponding to your Andersen Compact MotorTM Electric Winch, to determine the minimum wire size for your cables according to the total cable length required for your installation. If in doubt, consider choosing a thicker cable as this will help to minimise voltage drop. 6.4 Make up the cables with lugs to suit the terminals of your battery and the M8 terminals of the motor and circuit breaker. The circuit breaker can accept cable lug size for max. wire size 50mm2. STEP 7 Install the circuit breaker Ensure that the circuit breaker is switched to the "OFF" position before making any wiring connections. 7.1 Choose a suitable location for the circuit breaker [A11] in an easily accessible position as close as possible to the battery. 7.2 Connect the two thermal sensor wires from the motor to the terminals marked "TER. SW" on the back of the circuit breaker. 7.3 Use a 0.75mm2 wire to connect the terminal marked "MINUS" on the back of the circuit breaker to the NEGATIVE () terminal of the battery. Connect thermal sensor wires from motor Connect cable from Negative (-) terminal of the battery Circuit breaker wiring connections PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM STEP 8 Connect power and push button cables 8.1 NEGATIVE () BLACK connection from motor to battery: Connect the NEGATIVE () BLACK terminal of the motor to the NEGATIVE () BLACK terminal of the battery using the (-) BLACK power cable prepared in Step 6. Tighten the nut on the motor terminal to a maximum torque of 12Nm (9 ft lb). 8.2 POSITIVE (+) RED connection from motor to circuit breaker: Connect the POSITIVE (+) RED terminal of the motor to the terminal marked "+ MOTOR" on the circuit breaker using the (+) RED power cable prepared in Step 6. Tighten the nut on the motor terminal to a maximum of 12Nm (9 ft lb). Ensure that the cable lug is not touching the printed circuit board, and tighten the nut on the circuit breaker terminal to a maximum torque of 5Nm (4 ft lb). 8.3 POSITIVE (+) RED connection from circuit breaker to battery: With the circuit breaker switched to the "OFF" position, connect the terminal on the circuit breaker marked "+ BATTERY" to the POSITIVE (+) RED terminal of the battery using the (+) RED power cable prepared in Step 6. Ensure that the cable lug is not touching the printed circuit board, then tighten the nut on the circuit breaker terminal to a maximum torque of 5Nm (4 ft lb). 8.4 Connect the push button control cables [A10] to the short cable leads at the push button and the motor. Motor (-) Motor (+) Circuit Breaker, marked "+ BATTERY" Battery (-) Circuit Breaker, marked "+ MOTOR" Battery (+) 14 15 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM STEP 9 Check installation 9.1 The PCB at the rear of the circuit breaker is fitted with 3 LED indicators, located along its edge as indicated in the photo. Yellow LED The yellow LED may signal a status code by emitting a sequence of flashes once every 20 seconds. Count the number of flashes and refer to the Troubleshooting section of this manual. Red LED The red LED flashes when a fault has been detected. Refer to the Troubleshooting section of this manual. Green LED In normal operation the green LED illuminates continuously for the first 5 minutes after switching to "ON", and flashes once every 20 seconds thereafter. It will stop flashing a few seconds after switching the circuit breaker to "OFF". Pre-wired at factory LED Status Indicators Thermal sensor "Minus" (-) wire to wires to Motor Battery Negative (-) RED Positive (+) to Battery (+) LED status indicators RED Positive (+) to Motor (+) 9.2 Switch the circuit breaker to "ON". The green LED on the PCB at the rear of the circuit breaker should illuminate. Switch the circuit breaker back to "OFF". The green LED should go off after a few seconds. If this is not the case, refer to the table below. Fault Green LED does not illuminate. Green LED remains illuminated continuously for more than a few seconds after switching circuit breaker to OFF. Red LED flashes 4 times, followed by Green and Yellow both flashing. Possible Causes Circuit breaker is OFF, or there is a poor connection of MINUS wire from the circuit breaker to NEGATIVE (-) battery terminal. Cables on the circuit breaker terminals labelled MOTOR and BATTERY have been inverted. No MINUS wire connected, or incorrect/ faulty connections to the PCB terminals. Action Verify the connection of the MINUS wire, see step 7. Then check that the circuit breaker is ON. With the circuit breaker OFF, swap the cable connections to these terminals on the circuit breaker and then try again. Review details of steps 7 and 8, check all connections to the circuit breaker. 9.3 Verify that the push buttons are illuminated. If not, check connection of push button control cables. 9.4 With the circuit breaker switched to "ON", test the motor by pressing one of the push buttons. Bring the motor gradually up to half speed, and then gradually release pressure on the button until it slows to a stop. The motor and gearbox operation should be smooth and quiet. PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM STEP 10 Winch Installation 10.1 Use a hex key to remove the screws at the top of the winch, 1. 2. then lift off the self-tailing arm and the drum to expose the centre stem and gears, and remove the base cover ring. Position the centre stem of the winch on the deck plate with mounting holes aligned, and secure it to the deck plate. Then secure the base cover ring and fit the drum. 3. 4. Winch installation 10.2 Test the winch by rotating the drum by hand and operating the winch manually with handle. The winch should operate smoothly in both gears. Then remove the handle and test electrical operation by pressing the push button. 16 17 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Troubleshooting Compact MotorTM electric winches have built-in monitoring and protection features to enhance safety and avoid permanent damage to the electronic and mechanical components of the motor and winch. Automatic cut-out and reset The integrated controller will cause the motor to stop without tripping the circuit breaker if one of the following conditions is detected: · Maximum pulling load exceeded. The motor will cut out if the pre-set maximum pulling load of the winch for electrical operation is exceeded. Operation can resume within a few seconds when the load returns below the limit. · Overheating. The motor will cut out if the temperature of the motor circuit reaches 60°C (140°F). Operation can resume when the temperature returns to normal, which may take some time. · Maximum continuous run time exceeded. The motor will cut out after running continuously for 4 minutes and 15 seconds. Operation can resume after releasing the push button for a pause of at least 30 seconds. In these cases, the illuminated push button will flash, indicating that the controller will reset automatically when operating conditions return to normal. Fault detection and identification If a fault occurs that requires investigation or intervention, the LED indicators on the circuit breaker can assist with troubleshooting and diagnostics. These indicators are located along the edge of the PCB, at the rear of the circuit breaker as shown in step 9 of this manual. 18 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Troubleshooting Guide FAULT POSSIBLE CAUSE ACTION Excessive vibration or noise from motor/gearbox unit. Drive shaft housing not mating properly with octagonal recess in deck plate, clamping ring not tightened properly. Ensure proper assembly with deck plate, and sufficient clearance with through-deck hole see step 3. Ensure clamping ring is fully tightened before inserting and tightening locking grub screw. The motor has cut out after reaching the pre-set maximum load for electrical operation of the winch. Release the push button and run the winch with reduced load. Motor stops; push button LED flashes Motor circuit overheated; temperature above 60°C (140°F). When the motor has cooled down sufficiently (this may take some time), status will automatically reset to normal and the winch will be ready for use. Ensure adequate ventilation around the motor. Running time has exceeded +/- 4 minutes. Release the push button and start again after 30 seconds. Damaged control cable (push button to motor). Replace cable if necessary. Circuit breaker and/or battery switch may be "OFF". Check and switch to "ON". Motor will not start; push button LED not illuminated. No power supply to motor. Check power cables are properly connected to the battery and circuit breaker. Push button disconnected. Check control cables for push button and motor are connected. Motor will not start; push button LED is illuminated. Incorrect or insufficient voltage in power supply to motor. Damaged control cable (push button to motor). Restore normal voltage to power supply. Replace cable if necessary. Refer to LED Status Code table in this section of the manual. Address fault identified in LED Status Code table and reset the circuit breaker. Charge or change battery. Circuit breaker trips and switches to OFF after being reset. Incorrect or insufficient voltage in power supply to motor. Thermal sensor wires disconnected or damaged. Check terminal connections. Restore normal voltage to power supply and reset the circuit breaker. Re-connect thermal sensor wiring or replace if damaged. Motor circuit severely overheated; temperature above 70°C (158°F) trips circuit breaker to OFF. When the motor has cooled down sufficiently (this may take some time), status will automatically reset to normal and the winch will be ready for use. Ensure adequate ventilation around the motor. If problem persists or re-occurs contact your Andersen dealer. Circuit breaker trips and switches Refer to Status Code Table in this to OFF while operating the winch. section of the manual. Address fault identified in LED Status Code table and reset the circuit breaker. MINUS wire from circuit breaker to Green LED on circuit breaker does battery terminal is disconnected or not illuminate when circuit breaker damaged. switched to ON, or flashes every 20 seconds in normal use. PCB or its terminals may be damaged. Check cable and terminal connections at circuit breaker and battery. Contact your Andersen dealer, replace PCB if necessary. Circuit breaker trips, switches to Current draw exceeds maximum OFF and no status code flashes. rating of circuit breaker. Check electrical installation and ensure connections to circuit breaker are correct. Water drips from drain holes near Follow the instructions in the service kit for lip the base of drive shaft housing, May indicate water ingress through seal replacement provided with your Compact just above the motor/gearbox drive shaft lip seal. MotorTM, or contact your Andersen dealer for unit. assistance. 19 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM LED Status Codes / Diagnostics GREEN CONTINUOUS with circuit breaker ON CONTINUOUS with circuit breaker OFF FLASHING NOT ILLUMINATED circuit breaker ON NOT ILLUMINATED circuit breaker OFF In normal operation the green LED illuminates continuously for the first 5 minutes after switching the circuit breaker to ON, flashes once every 20 seconds thereafter and goes off a few seconds after switching the circuit breaker to OFF. In normal operation the green LED illuminates continuously for the first 5 minutes after switching to the circuit breaker to ON, and flashes once every 20 seconds thereafter. Circuit breaker wired incorrectly; positive (+) cable connections to terminals labelled MOTOR and BATTERY have been inverted. In normal operation, 5 minutes after switching the circuit breaker to ON the green LED will switch from continuous illumination to flashing once every 20 seconds. Circuit breaker wired incorrectly; positive (+) cable connections to terminals labelled MOTOR and BATTERY have been inverted. In normal operation the green LED will go off a few seconds after switching the circuit breaker to OFF. RED NOT ILLUMINATED FLASHING 4 times, then yellow LED starts flashing FLASHING yellow LED not flashing FLASHING 4 times, then green and yellow LED start flashing The red LED will illuminate if a fault is detected. If a status code is available it will be indicated by the flashing yellow LED. In normal operation the red LED will not be illuminated. Check Yellow LED status codes below. The circuit breaker can not be tripped by signal from PCB. Thermal sensor wires disconnected, or incorrect connection of positive (+) cables between motor, circuit breaker and battery. MINUS wire from circuit breaker to negative (-) battery terminal not connected, or incorrect/faulty connections to the PCB terminals. YELLOW 3 flashes 4 flashes 5 flashes 6 flashes The yellow LED signals a status code by emitting a sequence of flashes once every 20 seconds. High system voltage detected when power supply first connected. Exceeds pre-set limit for power up; check battery and any battery charging devices. High current draw detected when power supply first connected. Exceeds pre-set limit for power up; may indicate motor failure or incorrect wiring. Extremely low system voltage detected; check battery, charging devices and electrical installation. Low system voltage detected; check battery, charging devices and electrical installation. 7 flashes Continuous low current consumption ( 15 minutes), check electric installation. 8 flashes 9 flashes 10 flashes Continuous low current consumption ( 8 minutes), check electric installation. High system voltage detected during operation; check battery and any battery charging devices. Constant high system voltage detected; check battery and any battery charging devices. 11 flashes Status code not assigned. 12 flashes Status code not assigned. 13 flashes 14 flashes Motor overheated above 70°C (158°F), or damaged thermal sensor wiring. Circuit breaker wired incorrectly; positive (+) cable connections to terminals labelled MOTOR and BATTERY on the circuit breaker have been inverted. 20 PRODUCT MANUAL 46/50ST Below Deck Compact MotorTM Service and Maintenance Proper care and maintenance of your Andersen products will ensure many years of reliable service. For your Compact MotorTM unit it is essential that the following service procedures are carried out at the recommended intervals. Safety First! Always disconnect power before performing any service or maintenance work on an electric winch. Periodic lubrication of the motor drive shaft lip seal: Lubrication of the motor drive shaft lip seal is recommended once a year to condition the lip seal and avoid water ingress. To access the seal for lubrication, remove the winch from the deck plate. Liberally apply a high quality bearing grease such as Klüber Isoflex® TOPAS NB52. Andersen Winch Grease may also be used for annual lubrication. Isoflex® is a registered trademark of Klüber Lubrication München SE & Co. KG Liberally apply a high quality bearing grease Periodic replacement of the motor drive shaft lip seal Replacement of the motor drive shaft lip seal is recommended every 3 to 5 years, depending on usage, in order to avoid water ingress and ensure a long and trouble-free service life. In practice every 5 years will be sufficient for most users, while the shorter interval is advisable for winches that see more constant usage or are installed in more exposed installations. A service kit is provided with your new Compact MotorTM for the first lip seal replacement. It includes step-by-step instructions for the procedure and all necessary spare parts. Winch inspection & service Inspection and service of your Andersen winch is recommended at two year intervals. For information consult the separate product manual for your winch model which contains instructions, assembly diagrams and information about spare parts. Product manuals are available for download from the Andersen website. 21 Contact Andersen Stainless Steel Winches® are manufactured by Ronstan Denmark ApS. Jægervænget 36, 7100 Vejle Denmark info@andersenwinches.com WORLDWIDE DISTRIBUTION & SERVICE Visit www.andersenwinches.com WARRANTY Visit www.andersenwinches.com Andersen Stainless Steel Winches® is a registered trademark of Ronstan Denmark ApS