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OWNER'S MANUAL

Installation, Power Kit conversion, three-speed operation, wiring, status codes, servicing and parts for the Ronstan E2+ electric motor unit on the 45QT and 50QT three-speed Orbit Winches™, 12V and 24V.

DocumentRonstan 45QT & 50QT E2+ 3-Speed Electric Orbit Winch Product Manual
FormatPDF · 31 pages · 9.2 MB
LanguageEnglish
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Owner's ManualPDF · 31 p.Mounting dimensions template E2+ (1:1)PDF · 1 p.45QT 12V electrical data sheetPDF · 1 p.45QT 24V electrical data sheetPDF · 1 p.50QT 12V electrical data sheetPDF · 1 p.50QT 24V electrical data sheetPDF · 1 p.
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SpecificationsFeaturesInstallationPower KitThree-Speed ModeWiringQuickTrimServiceTroubleshootingProducts
Ronstan 45QT & 50QT E2+ 3-Speed Electric Orbit Winch — Product Manual

This manual is split into 2 pages: Part 1 · Part 2 →

Specifications

Item 45QT E2+ 50QT E2+
Electric winch (12V / 24V) RA645302100 / RA645302200 RA650302100 / RA650302200
Power Kit for an existing manual winch (12V / 24V) RA645352100 / RA645352200 (for RA6453) RA650352100 / RA650352200 (for RA6503)
Operation 3 speed manual, 3 speed electric 3 speed manual, 3 speed electric
Power ratio, 1st speed 6.3:1 6.3:1
Power ratio, 2nd speed 13.4:1 13.4:1
Power ratio, 3rd speed 45.5:1 49.3:1
Gear ratio 1st speed = 1.4:1, 2nd speed = 3.0:1, 3rd speed = 10.0:1 1st speed = 1.4:1, 2nd speed = 3.0:1, 3rd speed = 10.8:1
MWL 1200 kg (2650 lb) 1350 kg (2980 lb)
Rope diameter 8-14mm (5/16"-9/16") 8-14mm (5/16"-9/16")
Weight, winch only / winch & motor unit 5.9 kg (13.0 lb) / 19.3 kg (42.6 lb); data sheets 19.3kg (42.5lb) 5.9 kg (13.0 lb) / 19.3 kg (42.6 lb); data sheets 19.3kg (42.5lb)
Dimension (data sheets) Value
Drum Ø D 110mm (4 1/3")
Base Ø B 183mm (7 7/32")
Height H 207mm (8 5/32")
Line entry L 80mm (3 5/32")
Max. deck K 48mm (1 7/8"); extensions available to suit thicker decks
Gear length S 63mm (2 15/32")
Motor depth J 191mm (7 17/32")
Motor length N 303mm (11 15/16")
Motor offset (manual) mm in
Minimum Ox 255mm 10 1/16
Minimum Oy 95mm 3 3/4
Maximum Ox 339mm 13 11/32
Maximum Oy 122mm 4 13/16

Offsets with the motor in the optimum position to minimise Ox or Oy; Oy includes the push button cable and fitting on the motor housing. The motor rotates in 8 positions at 45° increments. The electrical data sheets print different offsets (minimum Ox 288mm with Oy 111mm; minimum Oy 96mm with Ox 301mm): check the real clearance under deck before cutting. Manual 996378 Rev.1.0.

Features

  • Internal controller and contactor: simple electrical connection. The winch can be serviced without removing the motor unit from the deck.
  • Two illuminated "intelligent" push buttons (Button 1 slow speed, Button 2 fast speed): LED shows system power is on and flashes status codes.
  • Integrated overload, thermal overload, accidental start, low voltage and continuous run time protection.
  • 3-speed manual operation is always possible with a standard winch handle; QuickTrim™ works with or without the handle.

Included & Required

  • Included: motor unit, winch (not in Power Kits), deck plate, drive gear, 2 push buttons with 500 mm (19 5/8") cable, 2 gaskets, label set, 6 x M4 x 20 screws, drilling template, manual.
  • Required: #2 Phillips screwdriver; Ø8.5mm drill for M8 (11/32" for 5/16"); Ø70 mm (2 3/4") hole-saw or jigsaw; 4mm and 6mm hex keys, 2mm hex key.
  • M8 or 5/16" Grade 316 fasteners, A4-70 hexagon socket cylinder head recommended, no more than 17.1Nm, with large Grade 316 washers or backing plate and Grade 316 nuts (the tools list says 5 of each, the installation steps 6: the template has 6 holes).
  • 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.

Installation

Deck Plate & Motor

  1. Position: smooth, flat surface; line entry 3-8° from horizontal; drive gear aligned to the line entry as on the drilling template.
  2. The E2+ winch is supplied with the deck plate fitted. Remove the self-tailing arm (latch back, slight anti-clockwise turn) and pull off the drum; remove the 5 screws and washers at the base of the centre stem (6mm hex key), lift the centre stem with the drive shaft off the deck plate and set aside the central gear assembly, the drive gear with axle pin, and the ratchet gear assembly.
  3. Place the drilling template with enough flat space for the deck plate and check the space below deck for the motor (dimensions above); a small pilot hole at the centre of the motor drive shaft helps. Choose one of the 8 motor positions.
  4. Drill Ø8.5mm holes for M8 bolts (Ø11/32" for 5/16") and cut the 70mm (2 3/4") hole for the drive shaft housing.
  5. Sealant under the deck plate around the holes; on metal or carbon fibre isolate it completely. Fit with large washers and nuts below deck, Tef-Gel™ under each fastener head, hex key on the fastener and spanner on the nut. 6 x M8 or 5/16" A4-70, no more than 17.1Nm. Deck fastenings are not supplied: length = deck plate + deck thickness + washers (or backing plate) and nuts.
  6. Motor (two people, one below and one above deck; correct alignment is essential, misalignment causes noise, vibration and premature bearing and gear wear): remove the 8 screws and washers from the top of the drive shaft housing (4mm hex key), pass the drive unit up through the deck and deck plate, rotate it to suit the cavity with the housing flange mating flush under the deck plate.
  7. Hold it in place and refit the 8 washers and M6 screws from above: medium strength thread lock, no more than 7.1Nm.

Winch on the Deck Plate

  1. Converting an existing manual winch with a Power Kit? Prepare it first (Power Kit Conversion below).
  2. Refit the ratchet gear assembly, the drive gear with axle pin, and the central gear assembly.
  3. Lightly grease the clutch plunger pin and insert it through the centre of the central gear sub-assembly, pointed end down; check it runs smoothly on the O-ring.
  4. Push the disconnection rod with circlip up through the drive shaft and the drive shaft water plug: its top sits flush with the top of the drive shaft.
  5. Set the centre stem over the deck plate with the 5 mounting holes aligned and fasten it with 4 of the 5 M8 x 20 screws and washers (hold one back for later use), Tef-Gel™ under each washer, no more than 17.1Nm.
  6. Slide the drum down, lay the closing washer in its recess (correct side up), and fit the self-tailing arm overhanging the rope splitter, closing plate rotated to align with the shaft; rotate slightly clockwise until it clicks. A visible red flash means the latch is not fully engaged.
  7. Checks: the drum turns smoothly clockwise by hand and not anti-clockwise; with a handle, clockwise gives the slowest speed and anti-clockwise the faster speed; the disconnection rod in the centre of the shaft depresses easily and returns when the handle is removed.

The drilling template (996230 deck plate template for all 45QT & 50QT E2+ models: 6 holes Ø8.30mm (5/16") on Ø156mm (6 5/32"), base plate Ø182mm (7 5/32"), motor cutout Ø70mm (2 3/4"), in the downloads) is drawn at 1:1 on A4: print it at 100% / actual size and check the printed copy against the dimensions on the sheet before drilling.

Power Kit Conversion of a Manual 45QT / 50QT

  1. Remove the self-tailing arm and drum, the 5 screws and washers at the base of the centre stem (6mm hex key), lift off the centre stem with the drive shaft, and set aside the central gear assembly, the drive gear with axle pin and the ratchet gear assembly.
  2. Central gear sub-assembly: grip the stainless steel lower shaft with pliers or a vice and apply heat to break the thread lock; gently prise the gear off with a flat screwdriver and push the new gear (supplied) onto the lower shaft. Keep the original gear in case you convert back to manual. The metal will be hot: wear suitable gloves.
  3. Drive shaft: grease the O-rings on the drive shaft water plug and insert it into the top of the drive shaft; use one of the centre stem screws to push it down until it is flush with the ridge inside the shaft, 28mm from the top.
  4. Deck plate: move the three stainless steel dowel pins from the original deck plate to the new one supplied with the Power Kit, slightly greased.
  5. Continue with the deck plate, motor and "Winch on the Deck Plate" steps above.

Using Three-Speed Mode

  • Fastest speed (first gear, 1.4:1 gear ratio): push down the button on top of the winch and turn the handle clockwise.
  • When the load becomes too heavy, turn the handle anti-clockwise to switch to second gear; the winch then shifts between second and third gear with handle direction.
  • Push the button again to return to first gear.
  • Avoid engaging the fastest speed when the winch is already under high load: disengagement in second gear can take significant effort. Easing the rope reduces the load.

Push Buttons & Electrical Connection

Fitting the Push Buttons

  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 Buttons to Motor (Detail A)

Motor cable Connect to Function
1 Brown Button 2 (fast speed) 1 Blue Switch
2 White Button 1 (slow speed) 1 Blue Switch
3 Green 3 Blue Black of both buttons Ground
4 Yellow 4 Red of both buttons LED
5 Grey No connection Acoustic working load alert (optional)
6 Pink No connection Not assigned

Battery Connection

Winch / supply Wire size by length * Circuit breaker Start-up motor current Additional battery capacity per winch Min. total battery bank
45QT 12V DC 35 mm2 (0-3m / 0-10ft); 50mm2 (3-8m / 10-27ft) 150A 600A 120Ah 300Ah
45QT 24V DC 25 mm2 (0-3m / 0-10ft); 35 mm2 (3-8m / 10-27ft) 70A 300A 60Ah 150Ah
50QT 12V DC 35 mm2 (0-3m / 0-10ft); 50mm2 (3-8m / 10-27ft) 150A 600A 53Ah (as printed) 300Ah
50QT 24V DC 25 mm2 (0-3m / 0-10ft); 35 mm2 (3-8m / 10-27ft) 70A 300A 53Ah 150Ah

* Wire length = total from battery to motor and back. Values from the manual table, which match the data sheets. Data sheet basis for the battery capacity: add the Ah of all other equipment and use 3 x the total as a rule of thumb; consult a qualified marine electrician.

  • Motor positive (+) terminal to battery positive (+), negative (-) to negative (-). Reversed polarity blows the motor controller internal fuse (see Troubleshooting).
  • Hold the nut closest to the motor with a spanner while tightening the outer nut on the cable terminal. If the inner nut turns, the isolation between motor and terminal can be damaged, voiding Ronstan's warranty on the electric motor.
  • Circuit breaker or fuse in the positive wire, as close to the battery as possible. A fuse must be "slow blow" / "long delay" to allow for the start-up current spike.
  • Never use smaller wire than the table: it can cause malfunction and, in the worst case, fire. Keep wires as short as possible.

QuickTrim™

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 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.

Service & Maintenance

General

  • 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.

Required for Service

  • Winch handle
  • Hex key 2mm for M3 fasteners (or 1/16" for 1/8")
  • Hex key 4mm for grub screws
  • Hex key 6mm for M8 fasteners (or 1/4" for 5/16")
  • Small flat screwdriver
  • White mineral spirits
  • ANDERSEN winch grease and a small brush
  • Medium strength thread lock adhesive

Servicing Steps

Overdrive (three-speed)

  1. Put the handle in the shaft and lift to expose the three stainless steel keys; remove them with pliers, turning the shaft to reach each. Lift out the drive shaft and remove the top clutch, overdrive gear and thrust washer.
  2. Remove both grub screws, springs and plungers; inspect and clean, lightly grease the plungers; on reassembly use medium strength thread lock on the grub screws, tight and flush with the centre stem (the steps call for a 6mm hex key, the tools list a 4mm key for the grub screws).
  3. With a 2mm hex key remove the three screws and washers from the overdrive gear and the retaining disc; separate the clutch, remove its pawls and springs, clean, very thin film of Andersen Winch Grease on the pawls, reassemble with the springs correctly oriented.
  4. Thrust washer in the groove under the overdrive gear, both into the bottom of the centre stem cut-out; top clutch into the side cut-out touching the bottom of the overdrive plunger (lift it: the overdrive button should protrude).
  5. Hold the top clutch approximately 10mm above the overdrive gear, drop the drive shaft in, insert the three keys and rotate the shaft until the keys engage the top clutch grooves and the shaft drops to its home position. Very thin film of grease on the overdrive gear and clutch.

Winch

  1. Shut off power to the winch. Remove the self-tailing arm and drum; check the latch works, inspect the self tailer (and QuickTrim™ action if enabled) and rinse in fresh water.
  2. Remove the ball bearing race and roller bearing, then the 5 screws and washers at the base of the centre stem (6mm hex key). Early winches may also have a retaining clip on top of the ratchet gear axle.
  3. Lift the centre stem with the drive shaft off the deck plate. Remove the clutch plunger pin, the central gear assembly, the drive gear with axle pin and the ratchet gear assembly.
  4. Strip the ratchet gear assembly (gear axle, bushing, washer, gear, two pawls and springs) and the central gear assembly (spacer, gear, two pawls and springs prised from the lower shaft). Keep each assembly's parts separate. Early ratchet gear versions have a lip on one face: fit it lip upward.
  5. Clean with a brush and white mineral spirits. Very thin film of Andersen Winch Grease on the pawls, springs correctly oriented; refit the gear and spacer on the lower shaft.
  6. Remove the disconnection rod with circlip from the drive shaft, grease it lightly and push it back up through the drive shaft and water plug, top flush with the drive shaft.
  7. Remove, lightly grease and refit the three stainless steel dowel pins. Reassemble in reverse, lightly greasing all gear teeth, drive shaft and axles; lightly grease the clutch plunger pin and insert it pointed end down.
  8. Fasten the centre stem with the washers and screws (6mm hex key), no more than 17.1Nm. Refit the roller bearing and ball bearing race (self-lubricating: do not grease), drum and arm, and check function.

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

  • Always shut off power before any service. The motor is a sealed unit; its internal parts need no regular servicing.
  • At the annual service, wrap a clean cloth on a finger and wipe inside the motor unit hole protruding through the deck plate to remove dirt, then apply a very thin layer of grease with a brush or cloth.
  • Inspect, clean and lubricate yearly the O-ring inside the drive shaft water plug and the two O-rings on the gear of the central gear sub-assembly; replace them if worn.

Troubleshooting

Protection & Status Codes

  • The E2+ 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.
Flashes Status What to do
1 Maximum working load reached: the motor cut out at the pre-set maximum load for electric operation Resets when the load drops below the limit and the button is pressed again
2 Low system voltage: below 10.5 Volts (12V) / 21 Volts (24V) at idle, or below 7.0 Volts (12V) / 18 Volts (24V) while running Recharge the batteries; resets when voltage is back above 11.0 Volts (12V) / 22 Volts (24V)
3 Motor maximum temperature reached Resets when the motor has cooled (may take some time); ventilate around the motor
4 Control board temperature above 85°C Resets below 75°C; ventilate around the motor
5 Push button error: a button was pressed when power was switched on Turn off power at the circuit breaker or battery switch, make sure no button is pressed, turn power on again
6 Maximum continuous run time reached (approximately 10 minutes) Release the push button, then press it again
7 Maximum relay cycles reached: the motor relay has been activated 20,000 times The relay must be replaced: contact Ronstan or your local Andersen Winches distributor

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.

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