Ronstan Compact Motor 68/72ST User manual

PRODUCT MANUAL
Compact Motor™
Above Deck
Electric Winch
68/72ST
FOR USE WITH:
Compact Motor™ Electric Winches
RA2068015100 RA2072015100
RA2068015200 RA2072015200
Compact Motor™ Conversion Kits
RA2068215100 RA2072215100
RA2068215200 RA2072215200
Winch Versions:
68ST (≥V.1.0) 72ST (≥V.1.0)
Your Winch Version No. __________________________________________
Your Motor Serial No. ______________________________________________
710208 Rev.1
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
2
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 nish and to deliver
season after season of reliable performance and sailing pleasure to
their owners through the years.
Compact Motor™ functionality
The Andersen Compact Motor™ is a brushless DC motor, carefully
matched to a low prole planetary gearbox, which requires less
space for installation and draws considerably less current than
traditional motor/gearbox congurations. Simplied electrical
installation requires no external control box.
The Compact Motor™ 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 ash, indicating that
the controller will reset automatically when operating conditions
return to normal.
Contents
PAGE
2Functionality
3 Safety notices
4Exploded view of assembly
and items included
5Parts list
6-10 Installation instructions –
motor and push button
11 Important notes - electrical installation
12 Wiring diagram
13-16 Electrical installation
17 Winch installation
18-19 Troubleshooting
20 LED status codes / diagnostics
21 Service and maintenance
22 Contact and warranty information
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3
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
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 signicant damage and/or serious injury if used
improperly or without due caution and vigilance.
Operators Must be Trained
Help prevent signicant 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 qualied to operate an electric winch must be kept at a safe distance from the winch and any
rigging or ttings 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 o power before attempting to resolve the
problem.
Avoid Accidental Operation
Always turn o 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 signicant damage and/or serious injury.
Maintenance
Turn o power to the winch before performing any maintenance or service tasks. Failure to do so could result in signicant
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 o, or leading to a suitable tting such as a cleat or bollard.
Failure to observe these precautions could result in serious injury
or death.
DO NOT DISCARD
SAFETY NOTICES
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
4
A4
A10
A1
A2
A5
A16
A14A12
A13
Exploded View
68/72ST Above Deck Compact Motor™ 12V/24V
4
2
3
1
Compact Motor™Above Deck
Winches, Size 68, 72 ST
Scale 1:1
Pagesize A2
ProductNo. RA2068015100 RA2068015200 RA2072015100 RA2072015200
IMPORTANT
Thistemplate document has been created at 1:1 scale. It is critical that
itis printed at 1:1 scale. Check any printed/reproduced copies match
thedimensions indicated at 1:1 scale prior to use.
HOLE DIAMETER PURPOSE
A 30mm Motorterminal RED positive (+)
B 30mm Motorterminal RED negative (-)
C 15mm Drainport
D 25mm Pushbuttoncontrol cable & thermal sensor
E 20mm Pushbutton control cable
ART No: RD100528
MountingDimensionTemplate Part No. RD100528 - Rev.3
Mounting Dimension Template
Andersen Winches
B
A
D
C
E
Ø10.5
8holes: Ø10.5mm (13/32”)
UseISO 4017-A4 - M10 bolts.
15mm+ deck thickness
+thread below deck.
Lowestpoint
(Drainport)
DCØ262.5
Dimensionsin mm unless otherwise indicated
PRODUCT MANUAL
Compact Motor™
Above Deck
Electric Winch
68/72ST
FOR USE WITH:
Compact Motor™ Electric Winches
RA2068015100 RA2072015100
RA2068015200 RA2072015200
Compact Motor™ Conversion Kits
RA2068215100 RA2072215100
RA2068215200 RA2072215200
Winch Versions:
68ST (≥V.1.0) 72ST(≥V.1.0)
Your Winch VersionNo. __________________________________________
Your Motor Serial No. ______________________________________________
Push Button - E1, Two Speed & Three Speed Electric Winches
Scale 1:1
Page size A4 (210mmW x 297mmH)
Product No’s RA582000, RA582010, RA582020
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”) o set to the centre
of the push button location (as indicated on the template).
RON-MDT/PBE1-Rev.2. 01-05-18
HOLE
Ø5mm
(3/16’’)
for breather
tube
12mm
(1/2’’)
20mm
(3/4’’)
HOLE
Ø19mm (3/4’’)
ON CENTRE
50mm
(1 15/16’’)
Cover in open position
50mm
(1 15/16’’)
2mm
(1/16’’)
37mm
(1 7/16’’)
3 HOLES
Ø3mm (1/8’’) TYP
25mm
(1’’)
50mm
(1 15/16’’)
HOLE
Ø25mm (1’’)
OFFSET 2mm from
centre of switch
9mm
(3/8’’)
Mounting Dimension Template
Andersen Winches™
A9 A15 A11A3 A3
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5
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
ITEM NO. QTY DESCRIPTION PART NO.
1 1 Motor Compact AD, 12V for 68-72ST RD827500
1 1 Motor Compact AD, 24V for 68-72ST RD827550
2 1 Base Cover, Stainless Steel
3 1 Gear set, freewheel high gear 893400
41 Gear set, freewheel low gear 893300
A1 2 Push button with plastic cover RA866000
A2 2 Push button gasket 735050
A3 1 Drilling template for 68-72ST Compact AD
A3 1 Drilling template for RA866000 push button
A4 1 Hex keys, metric
A5 6 Screw SS, M10x20 hex socket CSK head DIN7991-A4-M10X20
A9 1 Push button labels RD100029
A10 6 Screw M4x20mm, self tapping RD100025
A11 1 Product Manual
A12 2 Control cable, 1000mm (39”) RD877610
A13 1 Circuit breaker with integral controller 877750
A14 1 Drain tube RD877408
A15 1 Compact AD Seal Service Kit 68-72ST RA710027
A16 1 Terminal extension set, red & black 877800
OPTIONAL ACCESSORIES:
Push button, stainless steel cover RA866010
Push button, stainless steel cover with hole RA866020
Control cable extension, 1000mm (39”) RD877610
Control cable extension, 4000mm (157”) RD877611
Parts List
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
6
Required for installation
• Hex keys, metric (included)
• Cross head screwdrivers
• Drill bit Ø10.5mm for M10 mounting bolts (or drill bit 13/32” for 3/8” bolts)
• Drill bit Ø3mm (1/8’’)
• Hole saws Ø16mm, Ø20, Ø25mm and Ø30mm (5/8”, 13/16”, 1” and 1 3/16”)
• 8x ISO 4017-A4 M10 (3/8”) mounting bolts; (L = 15mm (5/8”) + deck thickness + thread below deck)
• 8x M10 (3/8”) locking nuts and large washers (or backing plate to match drilling template)
• Spanners: 13mm for motor and circuit breaker terminals, 17mm (9/16”) 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.
Winch production year and month [YY-MM] followed by
version number are stamped on winch base between
the mounting bolt holes.
Serial number engraved on bottom of motor.
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7
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
Installation Instructions
STEP 1
Determine the position of the winch and motor unit
1.1 Magnetic elds in the motor may aect compasses even
when the motor is not in use. Install the motor at least 1m
away from any compass, and always have your compass
recalibrated after installation.
1.2 Mounting of an Above Deck Compact Motor on a vertical
surface is not ideal as it increases exposure to potential
problems of excessive moisture and water ingress. It is
important to take care to protect the unit from unnecessary
exposure, and carry out seasonal maintenance and regular
lubrication of the motor shaft seal.
1.3 The winch should be positioned with the recommended
line entry angle of 3-8° from horizontal. Refer to the winch
product manual for details of correct line entry angle and
self-tailing arm positioning.
1.4 Refer to the Winch Data Sheet for your winch model for
clearance/space requirements for the wiring and drain tube
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.
1.5 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 [A14] will be attached to
this port to allow any moisture from condensation to escape
and drain to the bilge. The position of the drain port is also
indicated on the drilling template.
1.6 The self-tailing arm should be positioned to allow the rope
to drop clear of the winch as it feeds out of the self-tailer.
Positions will typically be as indicated by the shaded sectors in
the diagram.
3-8 degrees
Recommended line entry angle
Typical self-tailing arm positions
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
8
STEP 2
Prepare the mounting surface
2.1 After determining the mounting location and orientation, clean
the mounting surface and use the drilling template [A3] as a
guide. Ensure that the surface is at and there is adequate space
and clearance for operation of the winch.
2.2 With the drilling template in the desired orientation, drill the
Ø10.5mm holes for the M10 mounting bolts (or Ø13/32” holes
for 3/8” bolts).
2.3 Cut the required holes for the motor terminals, drain port and
wiring as indicated on the drilling template
2.4 Clean any wood or breglass splinters from the holes, and clean
the deck thoroughly to ensure deck sealant can adhere properly.
Drilling template use
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9
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
STEP 3
Prepare and dry-t the motor unit
3.1 Slide the stainless steel cover upward to remove it from the
motor unit (refer to the exploded diagram at the beginning of this
manual).
3.2 Fit the terminal extensions [A16] to the motor terminals,
ensuring that the RED extension is tted to the RED POSITIVE (+)
motor terminal, and the BLACK extension is tted to the BLACK
NEGATIVE (–) motor terminal.
3.3 Remove the plastic plug from the drain port tting and push the
drain tube [A14] into the tting 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 o any excess length. At most there should only
ever be a drop or two of water from condensation that will pass
through the tube.
3.4 Place the motor in position on deck. The two wires for the
thermal sensor can be passed through the 25mm hole together
with one of the push button control cables. The other push
button control cable is passed through the 20mm hole. Ensure
that deck cut-outs and fastener holes align properly and there is
adequate clearance for a good t and assembly.
Thermal Sensor wires
and Control Cable for
Push Button
RED terminal extension
tted to RED POSITIVE (+)
motor terminal
BLACK terminal extension
tted to BLACK NEGATIVE ( – )
motor terminal
Plastic plug
removed from
drain port
Drain
port
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
10
STEP 4
Install motor unit.
Having a second person to assist during this step may help to avoid fouling the wiring and drain tube with sealant as they are
passed through the deck.
4.1 Apply sealant to the deck to prevent water ingress. In addition to sealing the mounting holes, apply a bead of sealant
around the perimeter of the base to form a completely watertight seal.
NOTE: For mounting on metal surfaces, the base must also be completely isolated from the mounting surface to prevent
galvanic corrosion.
4.2 Fit the motor unit [1] to the deck using the appropriate length ISO 4017-A4 M10 or 3/8” bolts, large washers or backing
plate, and locking nuts.
4.3 Place the stainless steel cover [2] back on the motor unit and slide it down into position.
STEP 5
Install push buttons
The push buttons [A1] require 50mm clearance depth below the
mounting surface. They are supplied with a short 190mm (7 1/2”)
cable lead; each is connected below deck to a 1000mm (39”) long
control cable [A12] and then to one of 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 buttons [A1] are located in close proximity to the
winch, preferably within reach.
5.2 Determine the preferred orientation of the hinged covers (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 3mm (1/8”) hole in each of the mounting screw locations.
5.4 Fit gaskets and push buttons in place. Secure the push button
units with the M4x20mm self tapping screws [A10], 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.
Breather
channel
Drilling
template
Mounting
screws
Hinged
cover
Push
button
Rubber
gasket
Push button installation
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11
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
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 Motors™ 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 B™, 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 Motors™.
Super B™ 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 Motor™ 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 buttons to the Compact Motor™.
Extension cables may be ordered separately.
• Use only the Andersen circuit breaker supplied with your Compact Motor™; 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 Motor™ 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.
Important Notes - Electrical Installation
Incorrect electrical installation will result in permanent damage
to the motor and invalidation of the warranty.
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
12
Wiring Diagram
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!
WARNING
PUSH BUTTONS
(FAST & SLOW
SPEED) [A1]
CONTROL
CABLES
[A12]
WINCH
MOTOR
[1]
THERMAL
SENSOR
WIRES
CIRCUIT BREAKER
CONTROLLER
[A13]
BATTERY
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13
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
Drain port tting
with drain tube
Thermal sensor wiresControl cables
(connection to push buttons)
Negative (
-
)
Terminal BLACK
M8 Thread
Positive (+)
Terminal RED
M8 Thread
Motor Detail
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
14
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 Motor™
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
7.1 Choose a suitable location for the circuit breaker [A13] 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 0.75mm2wire to connect the terminal marked
“MINUS” on the back of the circuit breaker to the
NEGATIVE (–) terminal of the battery.
Ensure that the circuit breaker is switched
to the “OFF” position before making any
wiring connections.
Connect thermal sensor
wires from motor
Connect cable from Negative (-)
terminal of the battery
Circuit breaker wiring connections
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15
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
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 [A12] to the short cable
leads at the push buttons and the motor.
Motor (-) Battery (-)
Motor (+)
Circuit Breaker,
marked “+ BATTERY”
Circuit Breaker,
marked “+ MOTOR”
Battery (+)
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
16
STEP 9
Check installation
9.1 The PCB at the rear of the circuit breaker is tted 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 ashes once every 20 seconds. Count the
number of ashes and refer to the Troubleshooting
section of this manual.
Red LED
The red LED ashes 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 rst 5 minutes after switching to
“ON”, and ashes once every 20 seconds thereafter.
It will stop ashing a few seconds after switching the
circuit breaker to “OFF”.
Fault Possible Causes Action
Green LED does not illuminate. Circuit breaker is OFF, or there is a poor
connection of MINUS wire from the circuit
breaker to NEGATIVE (-) battery terminal.
Verify the connection of the MINUS
wire, see step 7. Then check that the
circuit breaker is ON.
Green LED remains illuminated
continuously for more than a
few seconds after switching
circuit breaker to OFF.
Cables on the circuit breaker terminals
labelled MOTOR and BATTERY have been
inverted.
With the circuit breaker OFF, swap the
cable connections to these terminals on
the circuit breaker and then try again.
Red LED ashes 4 times,
followed by Green and Yellow
both ashing.
No MINUS wire connected, or incorrect/
faulty connections to the PCB terminals.
Review details of steps 7 and 8, check all
connections to the circuit breaker.
RED
Positive (+)
to Motor (+)
RED
Positive (+)
to Battery (+)
Thermal sensor
wires to Motor
Pre-wired
at factory
“Minus” (-) wire to
Battery Negative (-)
LED Status
Indicators
LED status indicators
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 o after a few seconds. If this is not the case, refer to the
table below.
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.
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17
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
STEP 10
Winch Installation
10.1 Use a hex key to remove the screws at the top of the winch,
then lift o the self-tailing arm and the drum to expose the
centre stem and gears. Position the centre stem of the winch
on the motor unit with mounting holes aligned, Secure it to
the motor unit using the M10 countersunk head screws [A5]
provided, then t the drum to complete the assembly.
3. 4.
1. 2.
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 one of the push buttons.
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PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
18
Troubleshooting
Compact Motor™ 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 ash, indicating that the controller will reset automatically when operating
conditions return to normal.
Fault detection and identication
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.
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19
PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
FAULT POSSIBLE CAUSE ACTION
Excessive vibration or noise
from motor/gearbox unit. Mounting surface not at.
Relax tension on motor unit mounting bolts and try
running the motor. If this reduces noise/vibration,
rectify mounting surface and reinstall motor unit.
Motor stops;
push button LED ashes
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 circuit overheated;
temperature above 60˚C (140˚F).
When the motor has cooled down suciently (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.
Motor will not start; push button
LED not illuminated.
Circuit breaker and/or battery
switch may be “OFF”. Check and switch to “ON”.
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 insucient voltage in
power supply to motor. Restore normal voltage to power supply.
Damaged control cable (push
button to motor). Replace cable if necessary.
Circuit breaker trips and switches
to OFF after being reset.
Refer to LED Status Code table in
this section of the manual.
Address fault identied in LED Status Code table
and reset the circuit breaker.
Incorrect or insucient voltage in
power supply to motor.
Charge or change battery.
Check terminal connections.
Restore normal voltage to power supply and reset
the circuit breaker.
Thermal sensor wires disconnected
or damaged.
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 suciently (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
to OFF while operating the winch.
Refer to Status Code Table in this
section of the manual.
Address fault identied in LED Status Code table
and reset the circuit breaker.
Green LED on circuit breaker does
not illuminate when circuit breaker
switched to ON, or ashes every
20 seconds in normal use.
MINUS wire from circuit breaker to
battery terminal is disconnected or
damaged.
Check cable and terminal connections at circuit
breaker and battery.
PCB or its terminals may be
damaged.
Contact your Andersen dealer, replace PCB if
necessary.
Circuit breaker trips, switches to
OFF and no status code ashes.
Current draw exceeds maximum
rating of circuit breaker.
Check electrical installation and ensure connections
to circuit breaker are correct.
Troubleshooting Guide
All manuals and user guides at all-guides.com

PRODUCT MANUAL
68/72ST Above Deck Compact Motor™
20
GREEN
In normal operation the green LED illuminates continuously for the rst 5 minutes after
switching the circuit breaker to ON, ashes once every 20 seconds thereafter
and goes o a few seconds after switching the circuit breaker to OFF.
CONTINUOUS
with circuit breaker ON
In normal operation the green LED illuminates continuously for the rst 5 minutes after
switching to the circuit breaker to ON, and ashes once every 20 seconds thereafter.
CONTINUOUS
with circuit breaker OFF
Circuit breaker wired incorrectly; positive (+) cable connections to terminals labelled MOTOR
and BATTERY have been inverted.
FLASHING In normal operation, 5 minutes after switching the circuit breaker to ON the green LED will
switch from continuous illumination to ashing once every 20 seconds.
NOT ILLUMINATED
circuit breaker ON
Circuit breaker wired incorrectly; positive (+) cable connections to terminals labelled MOTOR
and BATTERY have been inverted.
NOT ILLUMINATED
circuit breaker OFF
In normal operation the green LED will go o a few seconds after switching the circuit
breaker to OFF.
RED The red LED will illuminate if a fault is detected. If a status code is available
it will be indicated by the ashing yellow LED.
NOT ILLUMINATED In normal operation the red LED will not be illuminated.
FLASHING 4 times, then yellow
LED starts ashing Check Yellow LED status codes below.
FLASHING
yellow LED not ashing
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.
FLASHING 4 times, then green
and yellow LED start ashing
MINUS wire from circuit breaker to negative (-) battery terminal not connected,
or incorrect/faulty connections to the PCB terminals.
YELLOW The yellow LED signals a status code by emitting a sequence of ashes once
every 20 seconds.
3 ashes High system voltage detected when power supply rst connected. Exceeds pre-set limit for
power up; check battery and any battery charging devices.
4 ashes High current draw detected when power supply rst connected. Exceeds pre-set limit for
power up; may indicate motor failure or incorrect wiring.
5 ashes Extremely low system voltage detected; check battery, charging devices and electrical
installation.
6 ashes Low system voltage detected; check battery, charging devices and electrical installation.
7 ashes Continuous low current consumption (≥ 15 minutes), check electric installation.
8 ashes Continuous low current consumption (≥ 8 minutes), check electric installation.
9 ashes High system voltage detected during operation; check battery and any battery charging
devices.
10 ashes Constant high system voltage detected; check battery and any battery charging devices.
11 ashes Status code not assigned.
12 ashes Status code not assigned.
13 ashes Motor overheated above 70°C (158˚F), or damaged thermal sensor wiring.
14 ashes Circuit breaker wired incorrectly; positive (+) cable connections to terminals labelled MOTOR
and BATTERY on the circuit breaker have been inverted.
LED Status Codes / Diagnostics
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