Lofrans XP800 Vertical Windlass — Installation & User's Manual
INSTALLATION MANUAL
Performance data, gipsy and chain/rope match, cable sizing and wiring, installation, operation, maintenance, troubleshooting, dimensions and the parts list for the Lofrans XP800 500W 12V vertical windlass with planetary gearmotor, with the deck template and wiring diagram.
DocumentLofrans XP800 Vertical Windlass Installation & User's Manual
FormatPDF · 18 pages · 1.1 MB
LanguageEnglish
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Technical Data
| XP800 | |
|---|---|
| Motor power | 500W |
| Up to vessel length | 11 m / 36 ft |
| Supply (power & command) | 12V |
| Maximum linear load/pull | 320 kg / 705 lb |
| Max lift working load | 95 kg / 210 lb |
| Amps at work load | 35 A |
| Max line speed | 21 m/min / 69 ft/min |
| Line speed | 17 m/min / 56 ft/min |
| Net weight, low profile | 10 kg |
| Gipsy | Chain supported | Rope supported |
|---|---|---|
| 6 mm | 6 mm ISO, 6 mm DIN 766, 3/16" BBB | 10–12–1/2" mm 3-strand; 14 mm 3-strand rope |
| 7 mm | 7 mm ISO, 7 mm DIN 766, 1/4" G4, 1/4" BBB | 10–12–1/2" mm 3-strand; 14 mm 3-strand rope |
| 8 mm | 8 mm ISO, 8 mm DIN 766, 5/16" G4, 5/16" BBB | 10–12–1/2" mm 3-strand; 14 mm 3-strand rope |
Electrical System
| Motor (W) | Voltage (V) | Contactor (A) | Cable 0–10 m / 0–33 ft (insulation rated ≥105°C) |
|---|---|---|---|
| 500 | 12 | 40 | 10 mm² / 8 AWG |
- Cable length is the total run, positive plus negative; maximum allowed voltage drop 10% for the power and command circuits.
- The gearmotor comes from the factory with 30 cm positive and negative leads; they need 6 mm crimp lugs.
- The two cables from the control box (green and black) connect with the crimp bullet connectors supplied; minimum section 2.5 mm² (14 AWG).
- Control box: dry, well ventilated place near the windlass, protected from direct water and away from flammable material (it can get hot).
- Circuit breakers: use the Lofrans breakers, chosen for their trip curve and not just a plate rating.
- Wiring diagram (separate download): footswitches DOWN (black) and UP (green), rocker switch type C, control box terminals M1, M2, B+ and B−, motor leads black and red, battery and a fuse on the command circuit.
Always disconnect electrical power to the windlass before any work on it.
Before You Drill
- In the box: windlass with gearmotor, control box (DC variants) and its cable crimps, handle.
- Also needed: circuit breaker and control switch.
- Tools: drill; 9 mm (23/64") and 12 mm (31/64") bits for wood and steel; 105 mm (4-1/8") and 50 mm (2") hole saws; 10 mm (3/8") wrench.
- Align the windlass precisely with the bow roller; bow roller height must keep the chain inclination below 5 degrees.
- The deck faces must be parallel; shim if they are not.
- With all the chain stowed, leave at least 300 mm between the underside of the deck and the top of the heaped chain.
- Deck thickness 10–30 mm with the standard studs; for thicker decks use longer studs.
- Aluminium boats: insulate the windlass from the deck with a non-conductive gasket (not supplied), and insulate anchor, chain, chain stopper and fixings from the hull.
Deck and Under Deck
- Place the drilling template on deck, aligned with the bow.
- Drill the 12 mm hole for the chain-counter sensor first, then the rest per the template: the stud holes and the 105 mm and 50 mm cut-outs.
- Leave the hole edges sharp, but radius the forward edge of the chain hole at 45°.
- Remove the template and seal the freshly cut hole edges with a marine sealant to keep water out of the deck.
- Screw the four studs fully into the windlass base (#1041c) and set the upper part on deck. Seal the base with silicone, never a permanent adhesive.
- Below deck: fit the washers and nuts on the studs and tighten; connect the gearmotor cables to the control box and battery per the wiring diagram.
Loading the Chain
- Feed the chain through the hole and secure it to a safe point.
- Wrap the chain round the gipsy.
- Recover all the chain under power, checking it enters the gipsy aligned.
Use calibrated chain matching the gipsy and always fit a swivel between chain and anchor.
Operation
Lowering
- Electrically: clutch tight, chain fixings off; switch on the safety switch and press DOWN; switch off and re-engage the fixings.
- By gravity: clutch tight, stoppers off, then ease the clutch with the handle. On the XP800, counterclockwise increases braking (to a full stop) and clockwise reduces it. Then secure the chain to a strong point.
- Always regulate the speed at which the windlass releases chain and anchor.
- Wait for the windlass to stop before reversing direction.
Recovery
- Breaker on, clutch tight, handle removed from the gipsy, stoppers off; press UP until the anchor seats in the bow roller, then breaker off and chain on the stopper.
- Run the engine or generator while recovering; do not rely on the batteries alone.
- The breaker does not protect the motor from overheating on long runs: respect the 5 min duty cycle and let the motor cool.
- If the breaker trips on overload, reset it and wait some minutes before running again.
Never use the windlass as a mooring point: hold the load on a chain stopper or a cleat.
Maintenance Programme
| Use of the yacht (months) | Less than 2 | From 2 up to 6 | More than 6 | Charter |
|---|---|---|---|---|
| Every 3 months | A – A (as printed) | A – B | A – B | |
| Every 6 months | A – B | |||
| Every 12 months | A – B – C | C | C | C – D |
| Every 24 months | D | D | E | |
| Every 36 months | D – E | E | E |
- A – Rinse all surfaces and hidden points with fresh water and a soft cloth or non-abrasive sponge. No chlorine, bleach or acid; polish the stainless parts.
- B – Grease the rotating parts with non-conductive yellow marine grease, especially the gearmotor main shaft threads and clutch cones. Anti-seize on the shaft and gypsy cap threads, studs and base, chain cap and the base screws.
- C – Check the crimps on the cables leaving the gearmotor water gland and test the voltage drop at the terminals.
- D – Replace the main seal on the base.
- E – Remove the windlass from the deck, clean the salt from under the base and re-seal.
- F – The planetary gearbox is grease-lubricated: no oil is required.
Gipsy Service / Replacement
- Turn the handle clockwise to remove the gypsy cap (#212).
- Remove the three M6 screws holding the chain cap (#1042) to the base; remove the chain cap and the stripper.
- Slide the gypsy and the lower clutch cone off the shaft.
- Wash with running water, never pressure-wash, and check for corrosion or mechanical stress.
- Reassemble in reverse order, greasing threads and all moving parts.
Disconnect power before any maintenance. Skipping the programme voids the warranty.
Troubleshooting
| Problem | Possible cause | Solution |
|---|---|---|
| Windlass does not run when a control is operated | Protection switch OFF; no voltage; control box, control panel or motor failure; gearmotor overheats and the breaker trips | Set the switch ON; check battery charge and connections; check/replace the control box or control; measure motor voltage – if OK, check and clean the brushes, otherwise replace the motor |
| Chain jams frequently | Locker too shallow for the chain carried; chain does not suit the gipsy; chain not calibrated | Fit the windlass over the deepest point of the locker or carry less chain; change the gypsy or the chain; replace chain that is out of tolerance |
| Runs slowly and sometimes trips the breaker | Cables too small; poor connections; water in the motor or planetary gearbox; gearbox lost its grease; motor strains; works in one direction only; electrobrake does not release properly | Increase cable section; check connections; replace the gearmotor; (service) inspect gearbox and motor; check for 12/24V between B2–C and B3–C on the control box when each button is pressed – if present and a relay does not work, replace the control box; check the gearmotor voltage |
| Gearmotor runs, shaft turns neither up nor down | Worn or damaged planetary gears; damaged gearmotor shaft | (Service) replace the planetary gearbox or the gearmotor, and other worn seals, screws and circlips |
| Clutch tight but the windlass cannot hold the anchor | Internal electrobrake malfunction | Remove the bottom plastic cover and check the internal wiring for a loose connection; replace the gearmotor |
| Motor and shaft turn, gypsy stays still | Gypsy not clamped on the clutch cones, or the closing wheel at end of travel; deformed cones with the hubs touching | Check clutch tightening, measure for deformation (shims can help), then replace the clutch and/or gypsy |
| Shaft runs out of true | Gearmotor shaft bent by excessive load | Check use is within the specification; (service) replace the planetary gearbox and worn parts |
Spare Parts
Item numbers refer to the exploded view. ✓ = included in the maintenance kit; "Finger kit" parts form the finger kit.
| Item | Description | Kit |
|---|---|---|
| 206E | Gypsy 8mm ISO4565/DIN766 #206B (as printed) | |
| 206F | Gypsy 7mm ISO4565/DIN766 #206D (as printed) | |
| 206A | Gypsy 6mm ISO4565/DIN766 #206F (as printed) | |
| 207 | Clutch cone – inner | |
| 208 | Ring DIN 17224 | |
| 212 | Gypsy cap, chromed | |
| 226 | Washer for M8 screw | ✓ |
| 227 | Nut M8 | ✓ |
| 231 | Washer for M5 screw | ✓ |
| 232 | Key 4×4×15 | ✓ |
| 293 | Hd cap screw M5×16 | Finger kit |
| 225a | Stud M8×58 | ✓ |
| 619 | Hd cap screw M6×10 | ✓ |
| 842a | Handle | |
| 906 | Spacer | Finger kit |
| 905A | Finger, nylon | Finger kit |
| 909 | Spring | Finger kit |
| 964 | Magnet | |
| 965 | Sensor | |
| 1008 | Pivot 7×14 | Finger kit |
| 1012 | Hd cap screw M6×40 | ✓ |
| 1041C | Base XP800, stainless | |
| 1042C | Chain cap, stainless | |
| 1044 | Stripper X1 | |
| 1046 | Ring seal 18-30-7 | ✓ |
| 2056 | Gearmotor XP800 | |
| 2057 | Countersunk screw M6×25 | ✓ |
| 2058 | Ring for screw M6×25 | ✓ |
Overall Dimensions & Deck Template
| Ref. | mm | inches |
|---|---|---|
| A | 90 | 3.54" |
| B (deck) | min 10 – max 30 | min 0.39" – max 1.18" |
| C | 305 | 12" |
| D | 103 | 4.05" |
| E | 145 | 5.70" |
| F | 197 | 7.75" |
- Deck template (separate download): 105 mm (4 1/8") and 51 mm (2") cut-outs, four 9 mm stud holes and the 12 mm sensor hole.
- Lofrans: the drawing should not be scaled – verify the dimensions of the print-out before drilling, and drill the 12 mm hole first.
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