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Botched winch install

GATORB8

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When looking for the running peak load of my Warn Zeon 10s, I found that it can run 465 amps. I don't think that was stalled. Fuse sizing guidelines suggest 125% of peak load. So a 600 amp fuse would be around the minimum.
I've definitely under fused the winch vs max at 300 amps. Should I ever have an issue with that and the fuse blow, it's simple to remove the fuse from the circuit with the post terminal I use for full power availabilty.

ANL's aren't too bad and are available in the 600 amp range.
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roaniecowpony

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I've definitely under fused the winch vs max at 300 amps. Should I ever have an issue with that and the fuse blow, it's simple to remove the fuse from the circuit with the post terminal I use for full power availabilty.

ANL's aren't too bad and are available in the 600 amp range.
Here's a link to some load data on the Warn 10.
[Complete Specs] Warn Zeon 10-S Platinum Winch 92815 Roundforge

600 amp fuse and holder
Eaton's Bussmann Series ANL-600 ANL Low Voltage Limiter Fuse | Waytek (waytekwire.com)
 

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TheRaven

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I've definitely under fused the winch vs max at 300 amps. Should I ever have an issue with that and the fuse blow, it's simple to remove the fuse from the circuit with the post terminal I use for full power availabilty.

ANL's aren't too bad and are available in the 600 amp range.
Not necessarily - Warn's winch disconnect kit, which is what they recommend for their Zeon's all the way up to the 12S Platinum, is rated for 200A. That's because the max rating is only peak amps and those numbers aren't seen for sustained periods - even the winch's own contactor isn't rated that high.


Um.. not that I see (not that I disagree that it's a solid safety addition)

https://www.warn.com/power-interrupt-kit-62132
 

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azjl#3

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Yeah so, I've never seen or heard of using a fuse on any winch in 50 years. Whys isn't there a fuse on the starter motor then? I do use battery solenoid cutout switches, always. Warn does not advice to USE a fuse, never seen them use a schematic showing one. At 600 amps, wouldn't the cable get pretty darn hot and melt that insulation anyway? There has to be some common sense here.
 

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Not necessarily - Warn's winch disconnect kit, which is what they recommend for their Zeon's all the way up to the 12S Platinum, is rated for 200A. That's because the max rating is only peak amps and those numbers aren't seen for sustained periods - even the winch's own contactor isn't rated that high.





https://www.warn.com/power-interrupt-kit-62132
I use that power interrupt but the argument can still be made that it doesn’t mention a winch in their description or the instructions if I am remembering correctly. “Allows you to connect aftermarket accessories to a battery lead and then disconnect power from a dash mounted switch. Recommended for extra protection.”
 

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Ignition source? The battery is on the same side of the vehicle as the winch solenoid. Is my frame going to catch fire? At least a dozen winch installs personally, hundreds of thousands of miles driven with winches, hundreds of pulls, 0 fuses, 0 switches, 0 melted wires, and 0 fires. Just like every winch manufacturer recommends. Just like hundreds of thousands of winches all over the world. If extra complexity, cost, and potential failure points during heavy pulls are your thing, go for it.
Same here for the last 24 years.
 
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TheRaven

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I use that power interrupt but the argument can still be made that it doesn’t mention a winch in their description or the instructions if I am remembering correctly. “Allows you to connect aftermarket accessories to a battery lead and then disconnect power from a dash mounted switch. Recommended for extra protection.”
The instructions for my Evo 10S mention it.
 

GATORB8

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Not necessarily - Warn's winch disconnect kit, which is what they recommend for their Zeon's all the way up to the 12S Platinum, is rated for 200A. That's because the max rating is only peak amps and those numbers aren't seen for sustained periods - even the winch's own contactor isn't rated that high.

https://www.warn.com/power-interrupt-kit-62132
Yeah, I previously had a PIK, and that's one of the reasons I was comfortable going with the 300 amp fuse. I ran out of Aux Switches and swapped to the fused setup.
 

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GATORB8

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The instructions for my Evo 10S mention it.
I thought that it might. I did look at both Zeon and Evo instruction pdfs on their site and didn't see it referenced.
 

TheRaven

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I thought that it might. I did look at both Xeon and Evo instruction pdfs on their site and didn't see it referenced.
That's the only way I knew it existed - I knew the (now former) director of product development at Warn and even he didn't mention it when he advised me on what to buy for my truck.
 

8ball

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To me it looks like no fuse, direct connect to battery
Ignition source? The battery is on the same side of the vehicle as the winch solenoid. Is my frame going to catch fire? At least a dozen winch installs personally, hundreds of thousands of miles driven with winches, hundreds of pulls, 0 fuses, 0 switches, 0 melted wires, and 0 fires. Just like every winch manufacturer recommends. Just like hundreds of thousands of winches all over the world. If extra complexity, cost, and potential failure points during heavy pulls are your thing, go for it.
You wouldn’t be touching anything I own…
Read up…. https://offroadpull.com/winch/fuse-need/
 

cosmokenney

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I am starting to feel really smart for listening to all the doomsday reports about not using a solenoid in my winch install. Yep I spent $50 for a Warn solenoid and took the time to wire it to an aux switch as a trigger. Starting to think a circuit breaker would be useful on the power line to the winch.
 

Zandcwhite

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You wouldn’t be touching anything I own…
Read up…. https://offroadpull.com/winch/fuse-need/
Wire yours however you want, I'll wire mine the way the vast majority have always been wired. Congratulations on finding an article on the internet that agrees with your fear. There's plenty of flat earth articles too so there's that.
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