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INSTALLATION MANUAL

Wiring layouts, switch options (DSS digital switches, BRS analog switches, DSS decoder), operating limits and the LED error table for the Harken Dual Function Control Box (DFCB) that drives Radial, Performa, Rewind, UniPower, Classic, FlatWinder™ and Captive electric winches.

DocumentHarken Dual Function Control Box Installation & User Manual
FormatPDF · 18 pages · 4.0 MB
LanguageEnglish
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Installation ManualPDF · 18 p.User Manual (9 languages)PDF · 94 p.
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OverviewInstallationWiring LayoutsOperation & SpecsLED Error CodesReading the LabelProducts
Harken Dual Function Control Box — Installation & User Manual

What the DFCB Does

The Dual Function Control Box is an electronic system that protects Harken electric winches from overload. When the factory-set load for the selected speed is reached, it cuts power to the motor for a preset time. Cut-off loads are factory set and differ with winch capacity. The DFCB is supplied with all standard-line winches; specific models are available on request for other product lines.

  • Each winch has its own DFCB – check the label for the correct association before installing.
  • DSS1 / DSS2: two MicroFit® plugs, one per Harken Digital System Switch (e.g. port and starboard helm).
  • BRS1 / BRS2: two Faston terminals for each standard Harken BRS (analog) switch.
  • DSS and BRS switches cannot be used at the same time: if a digital switch is connected, the standard inputs are disabled automatically.
  • Alarm LED shows operating status and error codes (table below).
  • Current monitor (optional): two connections for a Harken qualified operator to read motor current – not used for installation or normal use.
  • Serial number on the label is what Harken Technical Service needs for support.
  • For regulatory purposes the DFCB is a servo drive, not a safety device: the person operating the winch is responsible for the manoeuvre.

Mounting

  • Installation by qualified personnel only. Cut the power before starting.
  • Install below deck, in a dry place protected from the outside environment, where its condition can be checked.
  • Mount the box vertically, as far as space allows from other electrical and navigation equipment.
  • Footprint as printed: overall 132, mounting holes Ø6.50 (no unit given on the drawing).
  • Do not exceed the tightening torque of the motor cable lug lock nuts: 10 Nm.
  • Check the motor cables M1 / M2 are not swapped: an inverted connection makes the winch run at the wrong speed ratio.

Wiring Rules (all layouts)

  • All grounds (Batt−) to one point: Batt− of the DFCB to the battery negative.
  • Keep motor–DFCB and DFCB–HCP runs as short as possible.
  • Maximum switch cable length: 10m.
  • Never short-circuit BRS1 or BRS2 contacts to Batt+.
  • Connect only one BRS switch to each pair of terminals. For more BRS switches, contact Harken Technical Service.
  • To use BRS switches, remove the analog contact cover.
  • Cables, wiring and connections are not supplied by Harken: size cable sections for the run lengths and follow IEC regulations. Do not run Harken wiring in other multicable devices.
  • Test the system without load to identify the buttons for every winch speed before using the winch under load.

Wiring Layouts by Winch

The installation manual (main PDF) holds one diagram per configuration. Pick your figure:

Fig. Winch Switches / supply
1 Radial, Performa, Classic, FlatWinder™ 250 DSS (max 1+1)
2 Radial, Performa, Classic, FlatWinder™ 250 – 48V DSS (max 1+1); 48V main battery to motor via DFCB, 12 or 24V auxiliary battery to the DFCB side connector through a 5A circuit breaker
3 Rewind, FlatWinder™ 500 DSS (max 1+1); motor thermal protection
4 Rewind, FlatWinder™ 500 – 48V DSS (max 1+1); 48V main + 12 or 24V auxiliary (5A circuit breaker)
5 UniPower DSS; decoder not necessary for 2 or fewer switches
6 UniPower – 48V DSS (max 1+1); 48V main + 12 or 24V auxiliary (5A circuit breaker)
7 Radial, Performa, Classic, FlatWinder™ 250 BRS – do not use DSS
8 UniPower BRS – do not use DSS; motor thermal protection
9 Rewind, FlatWinder™ 500 BRS – do not use DSS; motor thermal protection
10 Radial, Performa, Rewind, UniPower, Classic, FlatWinder™ DSS with DSS decoder
11 Captive winch DSS (max 1+1); LMT-IN, LMT-OUT and SLACK sensors through the 6 ways connectors provided by Harken; motor thermal protection

More Than 2 Digital System Switches (Fig.10)

  • Do not connect any BRS switches.
  • Connect the DSS (decoder) outputs to the BRS1 and BRS2 inputs.
  • Motor connection follows the standard wiring scheme for your winch.
  • For UniPower winches use the Single DSS version.

The user manual states the decoder is necessary for 2 or more buttons, while the installation manual (Fig.5, Fig.10) gives it for more than 2 – check Fig.10 for your layout or ask Harken Technical Service.

Operation

  • Operation is identical for all winch series and sizes.
  • At switch-on the DFCB runs a 3 second self-test (wiring, battery voltage, internal functions); on error the winch is disabled and the LED signals the fault.
  • In use it compares motor current with preset limits. When the threshold is reached in the selected speed, power is cut for 5 seconds (first or second speed) – only that speed is locked out until the time has elapsed.
  • If the winch stops on overload, reduce the load before using it again.
  • Reversal time-out: minimum reversal time between speeds is 1.2 seconds.
  • Before use: check the DFCB and switches work, keep sight of the system and keep people and objects clear of moving parts.

Specifications / Conditions for Use

Parameter Value
Operating temperature -10 +60 °C
Storage temperature -10 +85 °C
Operating relative humidity 0 - 90 %
Operating voltage, 12 Vdc models 9 V - 16 V
Operating voltage, 24 Vdc models 18 V - 32 V
Low-battery cut-out, 12 Vdc models 9 V (reset above 10 V)
Low-battery cut-out, 24 Vdc models 18 V (reset above 20 V)
EMC Directive 2004/108/EC, harmonised standard EN 61000-6-2 (CE marked)

Diagnostics & LED Error Codes

  • Steady green LED: no error, device on and not enabled.
  • Slow-flash green LED: no error, device running.
Red LED flashes Error Solution
1 Battery under voltage / discharged Recharge the battery; check the device is compatible with the on-board system.
2 Current sensor error Contact Harken support / replace the device.
3 Coil error Contact Harken support / replace the device.
4 Internal system error Contact Harken support / replace the device.
5 Button pressed at start-up Release the button / check the wiring.
6 Two buttons pressed Release the buttons and press one only.
7 Internal system error Contact Harken support / replace the device.
8 Battery overvoltage Check the device is compatible with the on-board system.

If the winch runs at the wrong speed ratio, the motor cables are likely inverted: have the connections checked by Harken support.

DFCB Label Code: DF# XXXX YYYYY ZZ

Field Meaning
DF Dual Function Control Box
# Product specification: absent = for all winches; R = Racing Winch; C = Captive Reel Winch
XXXX Winch size or description
YYYYY Power supply voltage
ZZ Motor unit version: HR = horizontal right; HL = horizontal left; RL = horizontal right/left; V = vertical
  • Other labels: serial number; CUSTOM / SENSOR / COMMAND pole identification on the Captive Reel Winch version; "Auxiliary Batt + XX V" on the version for winches with 48 V motor (XX = auxiliary supply voltage, e.g. 12V); HW / FW = hardware and software version.

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

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