Winch (Zeon 10s) Shutoff Switch.

[SAReis]

Just go this for my winch shutoff switch. The specs were not listed on the site. The in-box documentation listed it as:
Continuous Rating: 275 Amps DC
Intermittent Rating: 455 Amps DC
Cranking Rating: 1250 Amps DC

Have any of you used one of these for a winch shutoff switch and is it within the specs of the Zeon 10s?

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[darkhorse13]

good info here: https://www.jeepgladiatorforum.com/forum/threads/winch-disconnect-switch.66748/

 

[cranbiz]

No, the specs of the Zeon 10 are 280A at 6000 lbs at one wrap on the drum. That switch is 275A continuous duty. I wouldn't do it. If you want a switch, get one good for a minimum of 500 A like this one.

https://www.amazon.com/Battery-Cont...+600A&qid=1698247456&s=automotive&sr=1-1&th=1

For a solenoid, get this one.
https://www.amazon.com/gp/product/B085RCCHDM/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

Here are the specs of a Zeon 10.

 

[SAReis]

No, the specs of the Zeon 10 are 280A at 6000 lbs at one wrap on the drum. That switch is 275A continuous duty. I wouldn't do it. If you want a switch, get one good for a minimum of 500 A like this one.

https://www.amazon.com/Battery-Continuous-Disconnect-Isolator-Position/dp/B093PFC5JN/ref=sr_1_1?keywords=Automotive+Replacement+Battery+Switches+600A&qid=1698247456&s=automotive&sr=1-1&th=1

For a solenoid, get this one.
https://www.amazon.com/gp/product/B085RCCHDM/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

Here are the specs of a Zeon 10.

Yeah, I figured. Just need to hear it from others sometimes. Thank you for the link to the 500 A switch.

 

[fourfa]

You're not going to find a consistent definition of "continuous" vs "intermittent" for automotive applications. In power delivery, "continuous" means literally 100% continuous duty cycle for days, weeks, months etc and some components are rated that way. Sometimes 5 min on, 5 min off duty cycle will be called continuous, other times intermittent. Winching loads in my experience are a lot less hardcore than that.

For what it's worth, inside my Warn VR 10 Evo is an Albright DC88-1074P contactor. This is considered a big upgrade from the old solenoid packs. If you have a look at the datasheet, you'll see it's rated for 100A continuous, 185A at 30% duty cycle, and rated for the full 360 amp stall current of the VR 10 Evo for ~100 seconds. So in this application, Warn thinks the winch load is intermittent, less than 100 seconds at a time.

By that definition, a shutoff switch rated 455 amps intermittent, 275 amps continuous, is enough for a winch rated 409 amps at stall. At 275 amps pulling 6000 lbs continuously - think about what that situation looks like. Even winching through miles of nonstop mud, stopping every hundred feet to re-rig the line takes it from continuous to intermittent.

I put a Bluesea 6006 on mine. Rated 300A i / 500A c. and does not even get warm with the worst winching I've done with it. Bluesea (not expensive, made in USA) gives me the warm fuzzies more than random amazon brands, but I probably wouldn't turn up my nose at the one in the OP either if I already had one lying around

TBH I was more concerned with the very long 2-gauge wires that Warn includes with their winches. My reading of the charts is that, using the same 100-second pull that the contactor is good for, 2g wires at the stock length limit the pull force to 8000 lbs (similar to a whole extra wrap on the drum). I made my own 1/0 wires, quality high strand cable, good lugs, very nice hydraulic crimper, exactly as short as possible. But to be fair this part is a lot more involved than just picking out a switch.

Warn themselves sell a 100A AMETEK SAS-4214 solenoid as their safety cutoff solution - IMHO that *is* perhaps undersize for their larger winches.

 

[m-l_johnny]

I’ve wondered about using a remote battery switch like this;

https://www.bluesea.com/products/7700/ML-RBS_Remote_Battery_Switch_with_Manual_Control_-_12V_DC_500A

But that’s a pretty salty price point for a little convenience

 

[cranbiz]

I run a 500A solenoid and control it with one of my Aux switches. This way, I don't have to open the hood.

 

[ShadowsPapa]

Just go this for my winch shutoff switch. The specs were not listed on the site. The in-box documentation listed it as:
Continuous Rating: 275 Amps DC
Intermittent Rating: 455 Amps DC
Cranking Rating: 1250 Amps DC

Have any of you used one of these for a winch shutoff switch and is it within the specs of the Zeon 10s?

It's what came with my Apex 12000 winch. I used it multiple times without issue.
I figure if it came with the winch.......... and there's a lot of them in use out there, and my digging didn't show failures or complaints (and believe me, if something fails, the internet will know about it!)

When I traded that truck in for my 2022, I went with a solenoid type wired to my aux switches, I needed a different setup for the space planning on a snow plow and other accessories so I went this route -

it made it handy when I did the plow install because I ran the plow main feed from the battery side of the winch solenoid. That means just one heavy cable to the battery + terminal instead of two. I'm using the solenoid as a terminal block.

i wouldn't have had much room for the large manual switch - although I kept it because it works fine and may use it elsewhere. It's a good heavy switch.

 

[SAReis]

Good to know. I thought about the solenoid option as well.

 

[AverageJoe]

I used a Warn 72631 winch solenoid and one of my auxiliary switches, much like Papa did. Works great if you have the aux switches!

 

[ShadowsPapa]

Yeah, either works fine. Solenoid (The Warn one AverageJoe mentioned) or the switch like shown (came with my Badland Apex 12000 winch)
It's a matter of preference, I guess.
I wanted to be able to turn mine on from inside, not slipping around on ice, in show or whatever, opening the hood. Granted, the hood bit is easier now with the hood struts I installed. One time when I used the winch I couldn't hold the hood up and use the prop rod because of the angle, and ice I was on.
There's so many ways to go!

 

[m-l_johnny]

So I’m guessing those of you using the solenoid aren’t having any issues with it overheating from being constantly energized? (While using the winch…).
I do like the idea…

 

[ShadowsPapa]

So I’m guessing those of you using the solenoid aren’t having any issues with it overheating from being constantly energized? (While using the winch…).
I do like the idea…

Keep in mind that even winches have a "duty cycle" and the load varies with the wraps of rope and load being applied.
I've not had trouble, though I've not maxed it out, either.
Warn sells them for their own winches...............

 

[fourfa]

The Warn 62132 power interrupt kit appears to be an Ametek SAS-4214. Warn (as typical for them) doesn't commit to any ratings at all in their docs. If you follow the datasheet and application guide the 4214 is only rated for 100A continuous, but 600A intermittent (which they define as "25% Maximum On Time, 2 Minutes Max" which is more than the 100 seconds Warn's Albright contactor is rated).

Reality is (as I've said above) if you manage to run your winch at stall for more than a few seconds, the rigging or the user is probably doing something wrong. 600A intermittent is more than enough

 

[cranbiz]

So I’m guessing those of you using the solenoid aren’t having any issues with it overheating from being constantly energized? (While using the winch…).
I do like the idea…

Not any problems yet and I use my winch frequently (on the JK with the same setup).

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