Darel
Well-Known Member
- First Name
- Darel
- Joined
- Apr 29, 2020
- Threads
- 51
- Messages
- 393
- Reaction score
- 299
- Location
- Mountain Top, PA
- Vehicle(s)
- '21 JT Rubi Sarge Green; '08 JK
- Occupation
- Military
- Thread starter
- #1
Just picked up a Warn Zeon 10-s and I wanted the ability to control it from both in the cab and with the handheld remote. Figured maybe I'd share this in case someone also wanted to do it.
I got a 5-lead waterproof cable and a waterproof bulkhead connector and mounted them in the contactor pack of the winch. I'm not thrilled with the location/position but there's not a lot of room inside the contactor pack. The 5 leads are just straight spliced into the wiring for the remote.
Now normally this would be easy to just control the in/out, but I was really concerned about what would happen if both aux switches got pressed at the same time, so I really overcomplicated this.
Basically to make this winch go out, you need to connect the red and white wires, and the brown and black wires inside the contactor pack. To go in, you connect red + green and brown + black. I have two DPST 12v relays, one for in and one for out, to do this. I could have wired these right into the aux switches and left it, but then if you accidentally push both buttons, I don't know what would happen. You'd almost certainly damage something. So what I did was wire the 12v coil of the DPST relays through a pair of SPDT relays. The leads are wired through the NC contacts on the SPDT relays, so that when you push the aux switches for In "control relay", it actually energizes the coil of the Out "safety relay", breaking the contact for the Out control relay. The way I have it wired, if you are winching in, and you accidentally press the out button simultaneously, both circuits open and the winch just stops, with nothing energized. As soon as you release one of the switches, the other one that you're still pressing re-engages and the winch continues to run.
The nice thing is you can still use the handheld remote, so now you've got options.
Rather than spend $90 on that heavy duty switch for disconnecting the power to the winch I just put a wing nut on the post on my battery bus, and only connect the power lead when needed.
I got a 5-lead waterproof cable and a waterproof bulkhead connector and mounted them in the contactor pack of the winch. I'm not thrilled with the location/position but there's not a lot of room inside the contactor pack. The 5 leads are just straight spliced into the wiring for the remote.
Now normally this would be easy to just control the in/out, but I was really concerned about what would happen if both aux switches got pressed at the same time, so I really overcomplicated this.
Basically to make this winch go out, you need to connect the red and white wires, and the brown and black wires inside the contactor pack. To go in, you connect red + green and brown + black. I have two DPST 12v relays, one for in and one for out, to do this. I could have wired these right into the aux switches and left it, but then if you accidentally push both buttons, I don't know what would happen. You'd almost certainly damage something. So what I did was wire the 12v coil of the DPST relays through a pair of SPDT relays. The leads are wired through the NC contacts on the SPDT relays, so that when you push the aux switches for In "control relay", it actually energizes the coil of the Out "safety relay", breaking the contact for the Out control relay. The way I have it wired, if you are winching in, and you accidentally press the out button simultaneously, both circuits open and the winch just stops, with nothing energized. As soon as you release one of the switches, the other one that you're still pressing re-engages and the winch continues to run.
The nice thing is you can still use the handheld remote, so now you've got options.
Rather than spend $90 on that heavy duty switch for disconnecting the power to the winch I just put a wing nut on the post on my battery bus, and only connect the power lead when needed.
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