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Introduction
While many new windlasses are sold complete with switching gear and circuit protection, we frequently get questions about installing new windlasses, as well as proper wiring and additional components.
Three Installation Questions
Proper windlass installation depends on three factors. First, determine whether you have a series-wound or permanent-magnet motor in your windlass. Permanent-magnet motors have two wire terminals on the motor. You change direction on the motor by reversing the polarity on the terminals. Series-wound motors have three terminals on the motor-two positive and one negative. Which direction the motor runs depends on which positive terminal is energized. The motor-type dictates which type of switching mechanism can be used to operate the windlass.
Second, determine whether you want single-direction (up-only) or dual-direction (up/down) operation. Many windlasses give you no choice-they are power-up/power-down by design. Others have a manual clutch that allows you to control the down direction, while some simply have free-fall. Since most boaters prefer the convenience of power-up/power-down operation, single-direction windlasses are becoming less common.
Finally, determine whether or not you want to be able to operate the windlass from a remote location. Sailors commonly weigh anchor from the bow, but on many powerboats it may be inconvenient to operate the windlass from the bow. On any boat it may be unsafe to stand on the deck in rough weather. Deck-mounted foot switches, located near the windlass, are used if remote operation is not desired. Panel switches at the helm are popular on powerboats, and hand remotes can be used on sail or powerboats when remote operation is desired.
Electrical Components
At the very least, every electric windlass circuit must have some sort of appropriately-sized circuit protection, either a fuse or a circuit breaker, as close as possible to the battery bank. The fuse or circuit breaker must be sized to handle the expected operating load, yet protect the wiring from a very high current draw and/or a short circuit. Remember that circuit protection will not protect the motor from sustained high load usage, which can cause heat build-up in the motor without tripping a breaker or blowing a fuse. Windlasses are designed to operate for short periods of time only.
Switches turn the circuit on or off, and differ in their current-carrying ability and their style. Current-carrying switches, like a foot switch or toggle switch, must handle the full current of the windlass. Non-current-carrying switches, like a panel switch or a hand-remote, turn a solenoid on or off, and must simply handle the solenoid current. A solenoid is an electric relay switch that opens or closes a main circuit when activated by a remote switch. Because windlasses draw large amounts of current, a solenoid allows the circuit to be "energized" from a remote location, without having to pass full current through the remote switch. A dual-direction switch box is made up of two solenoids and special switching gear capable of directing the current to make the windlass go up or down.
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