Announcement

Collapse
No announcement yet.

Winch overload device

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • Winch overload device

    I'm in the process of installing my winch and am fitting the controller in the engine bay - to do this my plan is to remove the three short cables and replace them with long cables and remove the long power cable and replace it with a short one - to make life simple (and save money) I was going to use the long power cable as the new winch red cable - sounds simple doesn't it?

    I knew the controller had overload protection and have just found out how it works - the short red winch cable has an insulated centre core which is connected to the outer wire at the winch end and to the overload device at the controller end - see photo below:



    At the controller end the overload device is connected to the red lead solenoid output, so that the overload device is effectively connected across the red winch cable.

    The main power cable that I was going to use doesn't have this centre core.

    I don't know if I can get this type of cable but I could run a separate sense wire alongside the red winch cable which would probably do the job.

    As the new red winch cable is longer I don't know if the overload device needs adjusting (there is a pot on it for adjustment) - and how do I do that?

    Or, I could just ditch the overload device.

    Anyone any suggestions on which way to go?

  • #2
    Interesting setup, it appears their measuring the voltage drop
    across the cable to determine the current being drawn by the
    winch.

    I would first measure the resistance of the inner wire to make
    sure it is just plain wire and not resistive.

    If this is the case I would just run another wire as you suggest.

    Re adjustment, going to be a bit hard to do unless you can find out
    the original setting from the manufacturer, ie the current flow through
    the red wire required to trip the device. You would then a clamp amp
    meter capable of reading the current and then find someway to load
    the winch and re-adjust current trip point. As long as the new cable
    is not to much longer than the original I wouldn't worry about it.

    Cheers
    LeighW
    HKB Electronics, manufacturer of the Alternator Voltage Booster, Silver 2008 D4D,Lifted,Underbody protection, Alternator Voltage Booster, Tiger Z winch, Lightforce DL, Air Horns, Tanami Drawers, Drop down fridge slide, Outback cargo barriers, Rotronics dual Battery system, Polaris GPS, HF/UHF/VHF, Radio speaker combiner, Long ranger water tank, Diff breathers, Inverter, Snorkel and others

    Comment


    • #3
      Thanks Leigh, I did measure the resistance of the sense wire and it was zero ohms so no worries there. The cable will be approximately 1 metre long rather than 300 mm so I guess the voltage drop could be out by a factor of three. I might just have to try it and see.

      Comment


      • #4
        If your worried about volt drop then upgrade the size of the cable...
        2014 D4D 150 GXL Automatic - CHARCOAL

        Comment


        • #5
          Originally posted by Matty & Loz View Post
          If your worried about volt drop then upgrade the size of the cable...
          That's not the issue Matty, the overload protection senses the voltage drop on the cable and shuts the system down if it goes above a certain limit effectively limiting the current. If I used a thicker cable the voltage drop would be less for the same current so the overload wouldn't work until a higher current was drawn potentially damaging the winch and negating the effect of the overload protection. In fact I am effectively using a thicker cable as the whole cable is being used rather than just the cable around the centre core if you see what I mean.

          Comment


          • #6
            Question: Is it electrically connected at both ends? That being can you measure electrical continuity between the smaller cores and the main connector lugs?

            Seems its more like a thermistor, maybe a K-J type? I've never heard of any protection ever using a voltage dropm in a protection system. Its not reliable enough and dependant on too many external factors.

            To test, connect a multimeter to the two small cores, set to ohms and apply a heat gun to the opposite end.

            EDIT: The resistance should increase as the cable gets hotter.
            2014 D4D 150 GXL Automatic - CHARCOAL

            Comment


            • #7
              The red cable to the winch consists of a small insulated cable down the centre of a much larger cable (effectively a coaxial cable but the screen is massive in comparison to the centre core). I've checked and the centre core is just a low impedance conductor. At the winch end both the centre core and the outer cable are connected together within the crimp. At the contactor end where the outer part of the red cable is connected there is a small wire going to the overload device. Also going to the overload device is the centre core of the red cable. The overload device measures the voltage difference between the two and must shut down if it's too great. I have seen current protection done in this way before but always using a completely separate sense wire.

              If you look at the photo in my first post you can see the centre cable and the extra connector at one end.
              Trekrider
              Banned
              Last edited by Trekrider; 11-08-2011, 08:07 PM.

              Comment


              • #8
                Just spotted something in the photo that may be causing confusion - the spade terminal at the right is just a single wire - what looks like a second connector is actually the remains of the heat shrink that was covering the join.

                Comment


                • #9
                  Yep, thats what had me mate. Was under the impression you had two connection there on the end.
                  2014 D4D 150 GXL Automatic - CHARCOAL

                  Comment


                  • #10
                    Originally posted by Matty & Loz View Post
                    Yep, thats what had me mate. Was under the impression you had two connection there on the end.
                    Yeh, sorry about that - suddenly realised when I looked back at the photo

                    Comment


                    • #11
                      Hi Trekrider,
                      Could just be as simple as a thermal fuse, that is cannected to the lug, and the other end supplies the positive to the control coil in the solenoid. If the lug gets too hot the fuse fails and the coil on the solenoid nolonger gets volts and cuts power to the winch motor. Here's an example of a thermal fuse (just the sinple aluminium axial can) If this is the case just need to find the temp rating of the fuse, usually written on the fuse, but it may be hidden in some sleaving. Would be surprised if they have gone for anything to complicated.

                      Matt
                      2003 Prado Grande TD Auto Pearl White

                      Comment


                      • #12
                        Thanks Matt, I've looked very closely at the way it's wired and it really is as simple as measuring the volts drop down the cable with the sense wire inside the power cable.

                        I've decided to just get rid of the overload protection as I have no way or recalibrating it and most winches don't have it any way.

                        Comment


                        • #13
                          Phew, coz I was just awfully confused and didn't know how to tell Matty that he needs to do the same for mine winch power cable. All good now,
                          [B][COLOR=blue]Bitumen: A blatant waste of taxpayers money![/COLOR][/B]
                          [URL="http://www.pradopoint.com/viewtopic.php?f=38&t=12197&start=0&st=0&sk=t&sd=d"]My rig buildup[/URL] [URL="http://www.pradopoint.com/album.php?albumid=141"]Mundaring Power Lines Jan 01[/URL] [URL="http://www.youtube.com/watch?v=KuQmi3Tgoe0&feature=feedu=d"]You Tube Video Morgan Quarry[/URL]

                          Comment

                          canli bahis siteleri bahis siteleri ecebet.net
                          mencisport.com
                          antalya escort
                          tsyd.org deneme bonusu veren siteler
                          deneme bonusu veren siteler
                          gaziantep escort
                          gaziantep escort
                          asyabahis maltcasino olabahis olabahis
                          erotik film izle Rus escort gaziantep rus escort
                          atasehir escort tuzla escort
                          sikis sex hatti
                          en iyi casino siteleri
                          deneme bonusu veren siteler
                          casibom
                          deneme bonusu veren siteler
                          deneme bonusu veren siteler
                          betticket istanbulbahis
                          Working...
                          X