Project 2000 - Electric winch Lofrans - Free user manual and instructions

Frequently Asked Questions - Project 2000 Lofrans

USER MANUAL Project 2000 Lofrans

Close-up of a stainless steel industrial vessel with chain links and a circular top, mounted on a curved metal platform (no visible text or symbols)

INSTRUCTION MANUAL

MANUEL D'INSTRUCTIONS

GEBRAUCHSANWEISUNG

Project 2000 presentation	Pg.3	Maintenance program	Pg.5
Safety information Pg.3 Limited international warranty Pg.5
Windlass wiring minimum requirements Pg.3 Wiring diagram Pg.18
Installation general requirements Pg.3 Pictures Pg.19
Installation procedure Pg.3 Exploded drawings Pg.20-22
Test procedure Pg.3 Part list Pg.21-23
Use of the windlass Pg.4 Lofrans sales organization		Pg.24

SOMMARIO

Thank you for choosing Lofrans. The Project 2000 is the new Lofrans windlass, designed for boat from 18 (59') up to 25 mts (82') length. Listed below are the technical features:

• Chromed Bronze finish as standard
  • Nominal power with S2 parameter 60 minutes : 2000W 24V
• Peak power with S2 parameter 1 minute : 4000W 24V
  • Available in AC motor : Three phases – Single phase (ask for details)
• Nickeled chain gipsy

• Cone clutches equipped
  • Main shaft in stainless steel AISI 431

• Base bearing in stainless steel AISI 440
  • Independent drum from gipsy

• Manual override equipped
  • Haulage speed : from 18 up to 24 mt/min
  • Ampere load : from 90 - 110 A
  • Max pull measured with dynamometer : Kgs 1800 approx
• Weight : Kgs 73

SAFETY INFORMATION

• This product is not designed as a strong point to fasten your anchor rode. Fast the anchor rode to a strong point such as mooring cleat or similar.
- The vessel's engine should always be running and used to assist in the recovery of the ground tackle.
• Always install the properly rated circuit breaker to protect the electric circuit and the motor from overheating and damage.
• Always turn off the main switch when the windlass is not in use to prevent accidental engagement.
• Always keep hands and feet clear of an operating windlass. If a jam occurs turn the windlass off at the main switch before clearing the anchor rode.
- Do not use the windlass for different purposes it was designed for.

WINDLASS WIRING MINIMUM REQUIREMENTS

Below there are the requirements for all the components of the windlass electric plant depending from the motor nominal power.

2000 W 24V

A-Battery capacity 150 Ah
B-Power cables size 50 mm^2 - 1 AWG
C-Lofrans Circuit breaker (slow time/current curve) 100 A
Fuse 5 A
Control wires size 1,5 mm^2 - 14 AWG

NOTES

A. Battery of lower capacity decrease the windlass performances and are rapidly subjected to wear and tear.
B. This size must be increased when the length of the positive plus the negative cables are more than 25 mts. Use marine grade tinned copper wire.
C. The Lofrans circuit breaker protects the power line from short circuit and the windlass motor in case of overheating. It must be kept dry and installed in accessible place to be promptly reactivated when it trips. It can be also used to isolate the windlass from the remote controls as we strongly suggest to avoid accidental engagement.
All the switches must be wired in parallel. We strongly recommend to have a minimum of two switches to operate the windlass in case one of them gets damage.
All Lofrans equipment is CE approved.

INSTALLATION GENERAL REQUIREMENTS

Proper installation of the windlass is critical and these essential conditions listed below need be fully satisfied :

Fig.1 The gipsy of the windlass must be in line with the bow roller.

Fig.2 The deck must be flat. The structure of the boat must be adequate to the load that the windlass is able to pull. If necessary reinforce the deck with a backing pad to spread the stress.

Fig.3 When determining the position of the windlass, it is critical to locate it directly above the deepest area of the chain locker. As the chain falls into the chain locker, it must be maximized because when the chain is stored. The chain tends to gather in the shape of a pyramid, which reduce the available space. If the chain pyramid falls, then overlaps may occur, resulting in jams. The deeper the locker, the less likely this will occur. You must have a minimum of A=12" between the underside of the deck and the top of the heaped chain. The chain locker shape is really important to limit the pyramid problem. The chain coming from the bow roller can be inclined up to 5 degrees.

INSTALLATION PROCEDURE

Fig.4 Carefully position the template provided to the deck. Mark and drill the holes as indicated (see Fig.A). Sand smooth all edges and seal (see Fig.B). Clean the deck area.

Fig.5 Loosen the 4 hex nuts (391) to separate the topworks from the gearbox and motor. Seal the windlass base with high quality sealant. Position the topworks on the deck.

Fig.6 Join the gearbox to the windlass topworks by inserting the main shaft into the way of the gearbox. Align the motor away from the chain pipe.

Fig.7 Fasten a washer, lock washer and hex nut to the remaining deck studs. Tighten all hardware properly. Connect the cables from the battery to the electric motor as shown in the electric diagram.

TEST PROCEDURE

Fig.8 Introduce the chain into the gipsy. Please take care to keep hands and feet away of the incoming chain.

Fig.9 Turn on the remote control. Operate the UP switch. The chain will be recovered. Release the UP switch. Operate the DOWN switch. The chain will be released. If the windlass runs in wrong direction change over the UP and DOWN wires at the control box.

Fig.10 After using the windlass, we strongly recommend that the nuts are checked again to ensure they are well tightened.

The basic operations you need to know are lowering and raising the anchor by electric motor. This product is cone clutch-equipped which allows to you to lower the anchor without using the electric motor. Lofrans strongly recommend to use the chain stopper in conjunction with this windlass. The chain stopper is a device which is normally installed on the boat and will keep your chain in place on deck. It must be used to secure the anchor after anchoring.

OPERATION FIRST ... THEN ...

1. USE OF THE CLUTCH	-	Low profile: to disengage the clutch insert the handle (884) into the star-shaped slot on the gipsy cap (944) and loosen it. To engage the clutch again tight the gipsy can until you cannot move the handle any more.Standard: to disengage the clutch insert the handle (884) supplied into the clutch nut (841) and loosen it. To engage the clutch tighten it until you cannot move the handle any more. Anchor and/or chain provide resistance during the tightening.
2. USE OF THE BRAKE	-	To disengage the brake loosen the hand-wheel (938). To engage the brake tight the hand-wheel. Always the band brake must be disengaged when you raise or lower the anchor and engaged at the end of these operation.
3. LOWERING THE ANCHOR BYTHE ELECTRIC MOTOR	Disengage the chain stopperCheck if the clutch is engagedDisengage the brakeTurn on the circuit breaker	Simple push the button DOWN.You will have always a perfect control of the operation, which can be interrupted any moment by releasing the button DOWN.
4. AFTER ANCHORING	Engage the chain stopperEngage the clutchTurn off the circuit breaker	If you have all chain, reduce the windlass load by engaging the chain stopper. If using a combination of rope and chain, fix the rope to a strong point such as a cleat. Engage the brake.
5. RAISING THE ANCHOR	Disengage the chain stopperCheck if the clutch is engagedDisengage the brakeTurn on the circuit breaker	Start the engine of the boat. Push the button UP while with the boat at minimum speed going towards the anchoring point.Do not use the windlass to pull the boat to the anchor. Release the button UP to stop the operation. Pay attention to the speed of the anchor, which may damage the bow of your boat. In the event that the anchor becomes stranded and the Lofrans circuit breaker trips, wait several minutes before re-setting and try once more. Should the circuit breaker trip again, we suggest to fix the rope or chain to a cleats and then use the boat engine to break the anchor loose.
6. DURING THE NAVIGATION	Engage the chain stopperEngage the clutchTurn off the circuit breaker	Windlass must not be used as the sole means of securing the anchor to the bow fitting.Anchors should be independently secured to prevent accidental release.Use a chain stopper or a lanyard to do that.
7. LOWERING THE ANCHOR BY THE CLUTCH	Disengage the chain stopperDisengage the brakeTurn off the circuit breaker	Disengage the clutch. As the chain falls, it can be controlled by the clutch handle. At the end of the operation engage the clutch.
8. USE THE DRUM	Engage the brakeTurn On the Circuit breaker	Disengage the clutch. Turn clockwise around the drum with 2-3 laps of rope.Keep the end of rope. Push the button UP, recovering the rope at the same time.
9. USE OF THE MANUAL EMERGENCY	Disengage the Chain stopperEngage the ClutchTurn Off the Circuit breaker	Insert the handle into the star-shaped slot (944 or 841) and turn it clockwise to exceed the gearbox springs strength (403). The stress will be hard in case of deep anchoring.

Below are indicated the operations and the period we consider essential to got the best efficiency and performance of your anchor windlass.

A. Clean all the outer surfaces and the hidden points with fresh water and remove the salt layer.
B. Grease the outer rotation parts . Particularly the main shaft thread and the clutch cones. Check for evidences of corrosion and stress.
C. Check the terminals of the electric motor. Test the drop of voltage at the terminals.
D. Replace of the all outer seals. The geabox is proper filled with SAE 90 long life oil.
E. Remove the windlass from the deck to clean the salt under the base plate.

	YEARLY FREQUENCY OF USE OF THE BOAT
	LESS THAN 2 MONTHS	FROM 2 TO 6 MONTHS	OVER 6 MONTHS	CHARTER
EVERY 3 MONTHS			A,B	A,B
EVERY 6 MONTHS		A,B
EVERY 12 MONTHS	A,B,C	C		C
AFTER 24 MONTHS		D	D	E
AFTER 36 MONTHS	D,E	E		E

LOFRANS LIMITED INTERNATIONAL WARRANTY

Lofrans warrants this product for a period of 2 years subjected to the conditions listed below :

1. The product must be registered. The registration must be done within 30 days from the date of purchase by one of these options: online going to the web site www.lofrans.com under the page "Product Registration" and following the instructions or by faxing to +039 2004299 the completed registration card attached to the instruction manual.
2. This warranty starts from the date of purchase of the product from the original purchaser. If the product is first equipment of a new boat the warranty starts from the date of purchase of the boat.
3. This warranty covers original defects in material and workmanship.
4. This warranty is limited to the repairment and/or the replacement of the original defective part.
5. The claim of warranty must be promptly notified in writing and sent by fax or e-mail to Lofrans or Lofrans authorised distributor providing the serial number of the product and the registration warranty number. Lofrans reserves the right to require the proof of purchase of the product to accept the claim of warranty.
6. The defective part/product must be returned to Lofrans or Lofrans authorized distributor. List of authorised distributors is available on the web site www.lofrans.com.
7. This warranty does not cover failures due to : use of the product in applications for which they are not intended , corrosion , normal wear and lear , discoloration , unauthorised alteration of the product , improper installation , incorrect use or maintenance of the product , conditions that exceed the product's performance specifications
8. This warranty does not cover any loss or damages to the original purchaser due to a proven non conformity of the product with the exception of the cases ruled by the Italian law.
9. Lofrans reserves the right to disclaim the warranty in case the product be controlled by improper electric devices and/or in case of non installation of a proper circuit breaker on the electric power line.

The consumer statutory rights are not affected by this warranty according to the national legislation, disciplining the sale of goods.

This warranty is ruled by the Italian law

For every controversy the Court of Milan is competent exclusively.

WIRING DIAGRAM WITH JUNCTION BOX

(x) Emergency switch Circuit breaker BATTERY JUNCTION BOX FOOTSWITCHES Rocker switch Project wire chain-counter Project radio chain-counter Polaris chain-counter (bty + 1 (Up) 2 (+) 3 (Down) 4 (-) 5 (Sensor) 1 (Up) 2 (+) 3 (Dw) 4 (-) 5 (Sn) 1 (Up) 2 (+) 3 (Dw) 4 (-) 5 (Sn) 1 (Up) 2 (Batter y +) 3 (Down) 1 (Up) 2 (Batter y +) 3 (Down) 1 (Up) 2 (Batter y +) 3 (Down) 1 (Up) 2 (Batter y +) 3 (Down) 1 (Up) 2 (Batter y +) 3 (Down) 1 (Up) 2 (Batter y +) 3 (Down) 1 (Up) 2 (Batter y +) 3 (Down) 1 (Up) 2 (Batter_y +) 3 (Down) 1 (Up) 2 (Batter_y +) 3 (Down) 1 (Up) 2 (Batter_y +) 3 (Down) 1 (Up) 2 (Batter_y +) 3 (Down) 1 (Up) 2 (Batter_y +) 3 (Down) 1 (Up) 2 (Batter_y +) 3 (Down) 1 (Up) 2 (Batter_y +) 3 (Down) 1 (Up)

WIRING DIAGRAM WITHOUT JUNCTION BOX

WINDLASSES (×) Emergency switch Circuit breaker BATTERY FUSE 5 A Polaris chain-counter 1 (Up) 2 (+) 3 (Down) 4 (-) 5 (Sn) FOOTSWITCHES Rocker switch Down + Up 1 (+) 2 (Up) 3 (Dw) Mira wire control Project radio chain-counter Merak radio control Battery + Up B2 B3 A1 B2 B3 A2 Project wire chain-counter 1 (Up) 2 (Battery +) 3 (Down) 5 (Sn) 4 (-)

These pictures are intended for guide only

Lofrans' WINDLASSES PROJECT 2000 CODE: B.26.101 - Rev. E date: 04 - 2007 LOW PROFILE STANDARD 884 841 879 1005 940 932 931 1026 953 869 954 389 391 390 392 260 226 944 865 365 A37 367 943 437 367 1030 939 937 938 1030 941 939 937 938 A02 935 375 866 867 954 869 953 869 934 942 876 877 878 879 880 453 234 407 395 1010 255 260 226 881 234 879 883 832 882

PROJECT 2000

Item Description Kit Q.tyltem Description Kit Q.ty
226 Washer for screw M8 Kit B 10 KA26101 Kit A - Seals 1
234 Hd cap screw - M8x20 Kit B 10 KB26101 Kit B - Screws&Nuts 1
255	Key - 6x6x25	Kit C	1
260	Spring washer for screw M8	Kit B	10
272	Handle		1
336	Oil plug 3/8"		1
351 Hd cap screw - M6x20 Kit B 2
361	Seal - 40x50x5	Kit A	1
365	Spring		1
367b	Gipsy chain 10 Iso - 3/8" G40		1
367c	Gipsy chain 3/8" Din766 - BBB - 10 Din766		1
367d	Gipsy chain 12 Iso - 13 Din766 - 1/2" Din766		1
367e Gipsy chain 1/2" G40			1
367f	Gipsy chain 1/2" BBB		1
367g	Gipsy chain 14 Iso		1
369	Washer for screw M10 Kit B 2
375	Dished plane spring		2
385 Hex hd screw M10x30 Kit B 2
386	Spring washer for screw M10	Kit B	2
389b	Stud - M10x170		4
390	Washer	Kit B	4
391	Nut - M10	Kit B	4
392 Hex hd screw - M8x25 Kit B 6
395	Seal - 50x70x10	Kit A	2
396	Bearing - 16010		2
399	Pawl		2
400	Circlip - 15 Din 471	Kit D	4
401	Pivot		2
402 Hex hd screw - M6x16 Kit B 3
403	Spring		2
407	Sightglass		1
414 Hex hd screw - M8x30 Kit B 4
437	Nylon band		1
449	Pivot		2
453	Bearing - 6206		1
632b	Bearing - 51108		1
841	Clutch nut		1
865	Clutch cone - outer		1
866	Clutch cone - inner		1
867	Seal - 40x68x10	Kit A	1
869	Circlip - 40 Din 471	Kit D	3
874	Gearcase - upper		1
875	O Ring seal - 4800	Kit A	1
876	Wormwheel		1
877	Ratchet		1
878	Gearcase - lower		1
879	O Ring seal - 159	Kit A	3
880	Oil level flange		1
881 Coupling flange 1
882	Worm		1
883	Spacer		1
884	Emergency handle		1
931	Base		1
932	Stripper		1
933	Cover		1
934	Main shaft		1
935	Band brake		1
936	Pivot		1
937	Brake pivot		1
938	Knob		1
939	Brake cover		1
940	Drum		1
941	Pivot		1
942	Main shaft		1
943	Clutch cone - outer		1
944	Gipsy cap		1
953	Bearing - 6008-2RS inox		2
954	Circlip - 68 Din 472 inox	Kit D	2
1005	Drum washer		1
1010	Electric motor 2000W 24V		1
1026	Plastic cap for sensor		1
1192	O Ring seal - 60-5 special		1

KC26101	Kit C - Keys		1
KD26101	Kit D - Circlips		1

Lofrans' WIND LABS PROJECT 2000 Sx. CODE: B.26.103 - Rev. E date: 04 - 2007 968 385 386 369 932 969 1026 953 869 954 389 390 391 874 392 260 226 414 260 226 234 881 361 879 883 632 882 338 878 395 453 879 880 234 407 970 971 972 879 1005 940 865 565 437 567 937 939 1030 936 935 402 449 876 399 400 401 402 1192 877 396 403 351 875 395 396 STANDARD LOW PROFILE

PROJECT 2000 SX.

Item Description Kit Q.tyltem Description Kit Q.ty
226 Washer for screw M8 Kit B 10 KA26101 Kit A - Seals 1
234 Hd cap screw - M8x20 Kit B 10 KB26101 Kit B - Screws&Nuts 1
255	Key - 6x6x25	Kit C	1
260	Spring washer for screw M8	Kit B	10
272	Handle		1
336	Oil plug 3/8"		1
351 Hd cap screw - M6x20 Kit B 2
361	Seal - 40x50x5	Kit A	1
365	Spring		1
367b	Gipsy chain 10 Iso - 3/8" G40		1
367c	Gipsy chain 3/8" Din766 - BBB - 10 Din766		1
367d	Gipsy chain 12 Iso - 13 Din766 - 1/2" Din766		1
367e Gipsy chain 1/2" G40			1
367f	Gipsy chain 1/2" BBB		1
367g	Gipsy chain 14 Iso		1
369	Washer for screw M10 Kit B 2
375	Dished plane spring		2
385 Hex hd screw - M10x30 Kit B 2
386	Spring washer for screw M10	Kit B	2
389b	Stud - M10x170		4
390	Washer	Kit B	4
391	Nut - M10	Kit B	4
392 Hex hd screw - M8x25 Kit B 6
395	Seal - 50x70x10	Kit A	2
396	Bearing - 16010		2
399	Pawl		2
400	Circlip - 15 Din 471	Kit D	4
401	Pivot		2
402 Hex hd screw - M6x16 Kit B 3
403	Spring		2
407	Sightglass		1
414 Hex hd screw - M8x30 Kit B 4
437	Nylon band		1
449	Pivot		2
453	Bearing - 6206		1
632b	Bearing - 51108		1
865	Clutch cone - outer		1
866	Clutch cone - inner		1
867	Seal - 40x68x10	Kit A	1
869	Circlip - 40 Din 471	Kit D	3
874	Gearcase - upper		1
875	O Ring seal - 4800	Kit A	1
876	Wormwheel		1
877	Ratchet		1
878	Gearcase - lower		1
879	O Ring seal - 159	Kit A	3
880	Oil level flange		1
881 Coupling flange 1
882	Worm		1
883	Spacer		1
884	Emergency handle		1
932	Stripper		1
935	Band brake		1
936	Pivot		1
937	Brake pivot		1
938	Knob		1
939	Brake cover		1
940	Drum		1
941	Pivot		1
943	Clutch cone - outer		1
953	Bearing - 6008-2RS inox		2
954	Circlip - 68 Din 472 inox	Kit D	2
968	Cover		1
969	Base		1
970a	Main shaft		1
971	Main shaft		1
972	Clutch nut		1
973	Gipsy cap		1
1005	Drum washer		1
1010	Electric motor 2000W 24V		1
1026	Plastic cap for sensor		1
1192	O Ring seal - 60-5 special		1

KC26101	Kit C - Keys		1
KD26101	Kit D - Circlips		1

LOFRANS' SALES ORGANIZATION

ARGENTINADOMINGO P. PEDRONI S.A.I.C.9 de Julio 198 - 1646 S. Fernando - Bs..As.	EGYPTMAPSO Marine Propulsion and Supply S.A.E.11(A) Mohamed Anis St.Zamalek - Cairo	GREECEALEX MARINE5 Leocharous Str.185 31 Piraeus	POLANDMAZURIA11 214 Galiny 2
AUSTRIAG.ASCHERL GmbHErlengrund 38 - 6971 HardHARTMANNHafenstrasse 5A - 6971 Hard a. Bodensee	ENGLANDE.C. SMITH & SONS LTD.Unit H & J Kingsway - Industrial Estate, KingswayLuton Beds , LU1 1LP	HONG KONGELCO MARINE & ENGINEERING LTD.20 Yip Fung StreetUnit 6 , G/F - Lincoln Centre - FanlingNew Territories HONG KONG	PORTUGALNAUTICORRua Bartolomeu Dias 172 A/D1400 Lisboa
BAHRAIN - ARABIAN GULF2000 MARINE STORESP.O. Box 26927Manama	FINLANDOY MARITIM ABP.O. Box 4600211 Helsinki 21	ISRAELATLANTIS MARINE LTD147 Kikar Atarim169 Hayarkon Str. - Tel Aviv 63453	SINGAPOREAMERICAN MARINE (S) PTE LTD.No. 26 Jalan TerusanJurong Town Singapore 2261
BELGIUMHUNTER N.V.St. Bernardsesteenveg 858-8642660 Hoboken (Antwerpen)	FRANCEACCASTILLAGE BERNARD880 Avenue Saint Exupéry06210 Mandelieu	LEBANONMARINE DIFFUSIONB.P. 8389 Beyrouth	SOUTH AFRICAMANEX & POWER MARINE (PTY) LTD.19 Dorsetshire Street - P.O. Box 1827420 Paarden Eiland-Cape Town
CANADAREKORD MARINE ENTERPRISES Ltd.8194 Ontario StreetVancouver B.C. V5X 3E3	AMIOT S.A.41, Quai Duguay-Trouin - Boîte Postale 10635407 Saint-Malo	MALTAINTERNATIONAL MARINE CENTRETa’Xbiex PalaceTestaferrata Street Msida	SPAINLA INDUSTRIAL VELERA MARSAL S.A.Muntadas 8 y 1008014 BarcelonaIMNASA S.A.Adva. Zaragozza 73/7517220 Sant Feliu de Giuxols (Girona)
CANARY ISLANDSNORDEST - Roberto OriggiAp. de Correo 1043138080 Santa Cruz de Tenerife	ELECTRIC-AUTO-YACHTING S.A.R.L.6, Rue de la Paix13001 Marseille	NEW CALEDONIELIMOUSIN MARINE70, R.te du Port Despointes-B. P. 701Noumea	SWEDENITALNORDICFöretagsvägen - Box 12440 90 Henan
CARIBBEANBUDGET MARINE N.V.P.O. Box 43425B Waterfront Road - Cole Bay - St. Maarten	R.E.Y.A.144, Avenue de la Roubine06150 Cannes-La Boca	NEW ZELANDEUROMARINEP.O. BOX 10144Dominion Road-Aukland 10	TAIWANGenco MARINE LTD.Suite 5F 5 169 Min Shen East Road, Sec.5P.O. Box 87-908 - Taipei Taiwan 10582
CROATIA -SLOVENJALUNIMAR S.r.l.Via Valdirivio 2634134 Trieste-Italy	SEIMI S.A.Rue Alain -ColasZIP-Port du Moulin Blanc - Boîte Postale 24329272 Brest	NEDERLANDSVETUS DEN OUDEN N.V.Fokkerstrat 5713125 Bd Schiedam	TURKEYCARKCI DENIZCILIK San.Ve.Tic.Ltd. Sti.Ozek skt tersalener yolu nuh sanayi sitesi 36Icmeler Tusla - Istambul
CYPRUSMERCURY DIVERS COMPANY LTD.15. Franklin Roosevelt Av. - Orphanides HouseP.O. Box 469 - Limassol	VIDAL DIFFUSION MARINEZ.I. Toulon ESTToulon Cedex 9	HUNGARYMIMOKER Co.Orso’ Utca 3H 1026 Budapest	U.S.A.IMTRA CORPORATION30 Samuel Barnet Blvd - New Bedford Industrial ParkNew Bedford Massachusetts 02745
DENMARKPALBY MARINE A/SBommerhavevej 41 SleldeDK 7100 Vejle	GERMANS.V.B.Gelsenkirchener st. 2528199 Bremen	NORWAYTELMO CONTROL A.S.Rolf Hofmos GT. 18 - Postboks 2906 Toyen0608 OSLO 6