Ronstan 40QT E1 Electric Orbit Winch — Product Manual

Features

• Internal controller and contactor: simple electrical connection. The winch can be serviced without removing the motor unit from the deck.
• Illuminated "intelligent" push button: LED shows system power is on and flashes status codes.
• Integrated overload, thermal overload, accidental start, low voltage and continuous run time protection.
• Two-speed manual operation always possible with a standard winch handle; clutch-less design lets the handle stay inserted during electric operation. QuickTrim™ works with or without the handle.

Included & Required

• Included: motor unit, deck plate, drive gear, push button with 500 mm (19 5/8") control cable, push button gasket, eye-bolt, drilling template.
• Required: #2 Phillips screwdriver; Ø6.5mm drill for M6 (9/32" for 1/4"); Ø54 mm (2 1/8") hole-saw or jigsaw; 4mm hex key (manual conversion only); 5mm hex key.
• 5x M6 or 1/4" Grade 316 fasteners (A4-70 hexagon socket head recommended, no more than 7.1Nm), 5 large Grade 316 washers or backing plate, 5 Grade 316 nuts, spanner.
• Solvent (white spirits), sealant, Tef-Gel™, medium strength thread lock, Ø3 mm (1/8") drill, Ø25 mm (1") drill or hole saw, crimping tool, marine grade power wire with Ø8mm terminals, circuit breaker/fuse (sold separately), cable clips.

Fitting the Push Button

1. The push button needs 25mm depth clearance behind the mounting surface. The button comes with 500mm (19 5/8") of cable and the motor unit with 1400mm (55 3/16") of control cable; beyond 1500mm (59") in total you must provide your own extension cabling.
2. Drill a Ø19 mm (3/4") hole at the centre of the button position plus a 5mm (3/16") hole right beside it for the breather tube, or a single Ø25mm (1") hole offset 2mm from the centre.
3. Using the gasket as a template, drill 3 x Ø3 mm (1/8") holes for the mounting screws.
4. Check the clear breather tube is inserted in the bottom of the push button.
5. Fit gasket and button (hinged cover opening upwards on a vertical surface), put a little sealing compound in the mounting holes and fasten with the 3 M4 x 20 CSK screws supplied .

Push Button to Motor

• Other motor wires: 2 White = switch 2 (2 speed motors only), 5 Grey = ratiometric current output, 6 Pink = low current cutout. Wires are marked with numbered sleeves.

Enabling QuickTrim™

• The winch leaves the factory with QuickTrim™ disabled: it works as a traditional self-tailing winch until you enable it.
• Remove the self-tailing arm, then the closing plate and closing washer.
• Locate and remove the countersunk cross-head screw shown in the manual. Keep it: refitting it disables QuickTrim™ again.
• Refit the self-tailing arm as in installation step 8.
• Once enabled, demonstrate the feature to new users before they use the winch.

Using QuickTrim™

• The winch tensions, eases and casts off like a traditional self-tailing winch; QuickTrim™ lets you make minor trim adjustments without removing the handle or taking the rope out of the self tailer.
• To ease: hold the tail of the rope in one hand; put the other hand on the top cover of the self tailer, fingers lying across the rope.
• Grip with the palm and rotate the top cover anti-clockwise against the spring pressure, and hold it there: the self tailer turns beneath the cover and the line eases off the drum in a controlled manner. Grip depends on load and number of wraps; you can assist the rope on the drum or use fewer wraps.
• At the right trim let the top cover spring back: the self tailer is locked again and the winch is ready for normal use.
• Designed for minor adjustments: useful where tension is adjusted often on sheets, halyards and other lines.

Winch

• Rinse with fresh water after each use to stop salt and contaminants building up.
• Complete service (dismantle, clean, lubricate) every two years; every year under extensive use such as racing, charter or extensive offshore sailing.
• Use ANDERSEN WINCH GREASE. Most other greases, including some labelled "marine grease", are not suitable and may cause a malfunction that could result in serious injury.
• Inspect the pawls and replace the springs every second year, with genuine Ronstan or Andersen pawls and springs only. Winch Pawl & Spring Kit RA710052 contains 8 pawls and 16 springs.

• Always shut off power before any service.
• Service the winch as the manual 40QT (arm and drum off, shaft out, pawls, gears, bearings): the roller bearing cassette and ball bearing race are self-lubricating and must not be greased; very thin film of Andersen Winch Grease on the pawls.

Malfunctioning pawls may let the winch release unexpectedly. Press each pawl against its spring: it must move smoothly and return by itself to engage the gear. If not, replace the springs and check again.

Electric Motor Unit

• The motor is a sealed unit; its internal parts need no regular servicing.
• Re-lubricate the drive shaft sealing ring once a year (twice a year under intensive use such as racing, charter or blue water sailing) to keep sea water out. Remove the winch from the deck plate to reach it.
• Grease: for example Klüber ISOFLEX TOPAS NB 52, or Andersen Winch Grease.
• Spindle nut socket tool 991023 and eye bolt RD100896 are installation aids: keep them for future use.

Protection & Status Codes

• The E1 motor unit has reverse polarity protection, mechanical overload protection, system low voltage detection, thermal overload protection, continuous run time limiting and accidental start protection.
• The illuminated "intelligent" push button flashes a status code: a number of quick flashes, a short break, then repeat.

Reverse Polarity: Replacing the Fuse

1. If the motor was connected with reversed polarity, its internal fuse has blown and must be replaced before the motor will start.
2. Remove the cable ties holding the control cable to the outside of the motor cover.
3. Remove the two screws at the end of the outer motor cover (#1 Phillips).
4. Rotate the cover slightly and pull it carefully away. After the first 5mm (3/16") the O-ring releases it; use very little force from there so the internal wiring is not damaged. Set the cover aside with no tension on the control wires.
5. Replace the 5A glass fuse on the PCB.
6. Reassemble in reverse: keep the internal cables clear of the cover, and align the cover screw holes with the threaded rods inside before pushing the cover over the O-ring.