Quick WIndlass failure, any ideas?

[dial-a-monkey]

Does anyone have any experience with a "Quick Antares windlass 1000W" failure? We have used it solidly for just 1 year - so I'm a little surprised that it's dead already? (no longer under warranty)

After it failed I discovered that the ETA hydraulic-magnetic circuit breaker is dead - so it didn't trip it just died
Weirdly? there's still 12 Volts on the dead side ..so it just that it won't pass enough current!!? - Investigating

When I replaced this circuit breaker the windlass worked fine for another day and then it died again killing the second (80 Euro) breaker - So I suspect the windlass motor is killing them. The relay "contactor unit" and remote still work correctly.

The batteries seem fine voltage wise - I guess I should test them under load?

I pulled apart windlass and measured (1) the resistance between windings @ 180 degrees and (2)windings to earth - all open-circuit and(3) between adjacent windings - all the resistances were very low and so my cheap meter couldn't distinguish between a short circuit and the winding resistance - which I would expect to be very low considering they are 1000 Watt windings - does anyone know if this is a correct assumption? Also there's NO sign of water or corrosion...Hmm...what happens to all the graphite floating around from wear to the brushes?

I also checked the windlass gear box manually - it turns with little resistance - so I don't think it's locking up and blowing the circuit breaker.( but I should spin it for a while in case something is loose in there)

Any other ideas anyone? Thanks for any suggestions, we're kinda marooned until I can find a 'Quick' ;~ solution ..

 

[Cardo]

This may or may not assist, but EU countries have to provide a minimum 2 year warranty on goods.

Though, if you are who I think you are, the item may not have come from the EU...

 

[dial-a-monkey]

G'day Tinkerbell - well spotted! - yea the windless is older than 1 year - but just wasn't used at all - the old chain was still in the packaging when we got it..Looks like it's been windy over your way Looks like you're good at surveillance

 

[dial-a-monkey]

Oh just another thought - If my relay is oscillating due to a bad contact - or just in general use from to the huge inductive load of the Windlass - Whats soaking up the Back EMF? I don't see anything in the circuit that would suppress the high voltage spikes that are surely being generated?

I guess that could be a reason why the circuit breaker was destroyed and didn't trip? Hmm could stick my meter over it set on AC and check if I get spikes.

EDIT - Today I opened the hydraulic-magnetic circuit breakers both had obvious signs of high voltage arcing - the contacts are burnt and there is the black soot from the corona of a spark. ( Photos attached) - 1000 grit sandpaper resuscitated one of the circuit breakers - but despite the same symptoms I wasn't able fix the second breaker - Even after re-soldering some of the joints it still fails to pass current correctly( the voltage looks good)

I have a few "Mega 100amp" fuses which fit well over the rear bolt 'legs' so I'm no longer marooned..But it's looking like the relay "contactor unit" is oscillating causing some high voltage spikes...so it 's definitely a stupid idea to use a fuse that isn't voltage sensitive...

There must also be arcing on the relay too - but I think it's harder to get to the contacts than it is for the breakers - tomorrow I pull the relay and look for problems on the armature.