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Dean Gillies
Hi Amelians,
I'm having a problem with the chain counter sensor of my Lewmar V4/5 windlass (Amel 54). The control head unit in the cockpit is the AA560. I assume this sensor is just a reed switch which triggers with each rotation of the gypsy as the magnet passes overhead.
The problem shows up as random counting (and beeping) and the diagnostic check shows the sensor output being "unstable". The voltages displaying on the AA560 diagnostic check are unstable, flickering between 4.8-5.0V on the red connection and 0-2V on the black connection.
So, it looks like I have either a faulty sensor or a problem in the wiring/connectors. I have checked the cable connections at the terminal block behind the AA560 head unit and they look fine.
In the fore-locker I can see the grey cable coming out of the windlass bottom plate where the sensor is located. The cable (along with the main power cabling for the windlass motor) then runs into some conduits and around into the switch panel in the box in the aft starboard corner of the fore-locker.
It seems to run through that locker (difficult to see) and out into a conduit that runs across the top of the locker and then aft into the boat.
The questions in my mind at the moment:
Is there a connector somewhere along this sensor cable run that could be faulty, or is it a single cable run from the sensor to the terminal block behind the control head?
Is it easy to remove that sensor from the windlass plate? How? Is it glued in there?
Has someone trodden this path before me and can offer some guidance?
In the meantime, I will disconnect the cable behind the control head to stop the beeping!
Many thanks
--
Dean Gillies
SV Stella *****, Amel 54-154
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Hi Dean,
I can’t answer about routing of sensor cable but can give you idea as I changed mine sensor recently
Before you change sensor check magnet on gipsy. Some time dirt is accumulating there.
Sensor is glued or use silicon but be careful with the distance from gipsy when you installing Should not be too far away from surface as will not ‘see’ magnet.
Hope this helps.
Best Regards,
Vladan
A54 #157
SV PAME
toggle quoted message
Show quoted text
From: main@AmelYachtOwners.groups.io <main@AmelYachtOwners.groups.io> on behalf of Dean Gillies <stella@...>
Sent: Friday, June 3, 2022 9:28:50 AM
To: main@AmelYachtOwners.groups.io <main@AmelYachtOwners.groups.io>
Subject: [AmelYachtOwners] Chain Counter Sensor Connector A54
Hi Amelians,
I'm having a problem with the chain counter sensor of my Lewmar V4/5 windlass (Amel 54). The control head unit in the cockpit is the AA560. I assume this sensor is just a reed switch which triggers with each rotation of the gypsy as the magnet passes overhead.
The problem shows up as random counting (and beeping) and the diagnostic check shows the sensor output being "unstable". The voltages displaying on the AA560 diagnostic check are unstable, flickering between 4.8-5.0V on the red connection and 0-2V on the black
connection.
So, it looks like I have either a faulty sensor or a problem in the wiring/connectors. I have checked the cable connections at the terminal block behind the AA560 head unit and they look fine.
In the fore-locker I can see the grey cable coming out of the windlass bottom plate where the sensor is located. The cable (along with the main power cabling for the windlass motor) then runs into some conduits and around into the switch panel in the box in
the aft starboard corner of the fore-locker.
It seems to run through that locker (difficult to see) and out into a conduit that runs across the top of the locker and then aft into the boat.
The questions in my mind at the moment:
Is there a connector somewhere along this sensor cable run that could be faulty, or is it a single cable run from the sensor to the terminal block behind the control head?
Is it easy to remove that sensor from the windlass plate? How? Is it glued in there?
Has someone trodden this path before me and can offer some guidance?
In the meantime, I will disconnect the cable behind the control head to stop the beeping!
Many thanks
--
Dean Gillies
SV Stella *****, Amel 54-154
-- Vladan A54 #157 SV PAME
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Dimitris Krasopoulos
Push the connector up it has the tendency to fall put some chewing gum or some plastic clay to keep it in place as much up as possible. The magnet in the gypsy is easy to inspect . It can be damaged from the salt and can easily been replaced if necessary. Do not turn the Gypsy upside down as the position of the magnet is different and you are going to have no signal at all
================= Στάλθηκε από το iPhone of Dimitris Krasopoulos Mob Greek +306944302318 Mob Dubai +971564602575
On Jun 3, 2022, at 9:28 AM, Dean Gillies <stella@...> wrote:
Hi Amelians,
I'm having a problem with the chain counter sensor of my Lewmar V4/5 windlass (Amel 54). The control head unit in the cockpit is the AA560. I assume this sensor is just a reed switch which triggers with each rotation of the gypsy as the magnet passes overhead.
The problem shows up as random counting (and beeping) and the diagnostic check shows the sensor output being "unstable". The voltages displaying on the AA560 diagnostic check are unstable, flickering between 4.8-5.0V on the red connection and 0-2V on the black connection.
So, it looks like I have either a faulty sensor or a problem in the wiring/connectors. I have checked the cable connections at the terminal block behind the AA560 head unit and they look fine.
In the fore-locker I can see the grey cable coming out of the windlass bottom plate where the sensor is located. The cable (along with the main power cabling for the windlass motor) then runs into some conduits and around into the switch panel in the box in the aft starboard corner of the fore-locker.
It seems to run through that locker (difficult to see) and out into a conduit that runs across the top of the locker and then aft into the boat.
The questions in my mind at the moment:
Is there a connector somewhere along this sensor cable run that could be faulty, or is it a single cable run from the sensor to the terminal block behind the control head?
Is it easy to remove that sensor from the windlass plate? How? Is it glued in there?
Has someone trodden this path before me and can offer some guidance?
In the meantime, I will disconnect the cable behind the control head to stop the beeping!
Many thanks
--
Dean Gillies
SV Stella *****, Amel 54-154
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|
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Nick Newington
Hi Dean,
I replaced my non functioning Lewmar chain counter with the Lofrans version (Iris) a couple of years ago. Has been perfect ever since. I changed the sensor and the magnet. The sensor is mounted from below the windlass. I tried yanking the old one out by the wire but broke it. So I drilled it out. I then inserted the new one and sealed it in place with silicon.
I then spliced the new cables to old with solder and heat shrink tubing.
The magnet too, which is on the gypsy got drilled out and a new one epoxied in its place.
The whole installation up forward was pretty easy. The wiring above the galley sink was harder, from a dexterity point of view.
Nick S/Y Amelia AML54-019
On 3 Jun 2022, at 10:55, Dimitris Krasopoulos <dkrasopoulos@...> wrote:
Push the connector up it has the tendency to fall put some chewing gum or some plastic clay to keep it in place as much up as possible. The magnet in the gypsy is easy to inspect . It can be damaged from the salt and can easily been replaced if necessary. Do not turn the Gypsy upside down as the position of the magnet is different and you are going to have no signal at all
================= Στάλθηκε από το iPhone of Dimitris Krasopoulos Mob Greek +306944302318 Mob Dubai +971564602575 On Jun 3, 2022, at 9:28 AM, Dean Gillies <stella@...> wrote:
Hi Amelians,
I'm having a problem with the chain counter sensor of my Lewmar V4/5 windlass (Amel 54). The control head unit in the cockpit is the AA560. I assume this sensor is just a reed switch which triggers with each rotation of the gypsy as the magnet passes overhead.
The problem shows up as random counting (and beeping) and the diagnostic check shows the sensor output being "unstable". The voltages displaying on the AA560 diagnostic check are unstable, flickering between 4.8-5.0V on the red connection and 0-2V on the black connection.
So, it looks like I have either a faulty sensor or a problem in the wiring/connectors. I have checked the cable connections at the terminal block behind the AA560 head unit and they look fine.
In the fore-locker I can see the grey cable coming out of the windlass bottom plate where the sensor is located. The cable (along with the main power cabling for the windlass motor) then runs into some conduits and around into the switch panel in the box in the aft starboard corner of the fore-locker.
It seems to run through that locker (difficult to see) and out into a conduit that runs across the top of the locker and then aft into the boat.
The questions in my mind at the moment:
Is there a connector somewhere along this sensor cable run that could be faulty, or is it a single cable run from the sensor to the terminal block behind the control head?
Is it easy to remove that sensor from the windlass plate? How? Is it glued in there?
Has someone trodden this path before me and can offer some guidance?
In the meantime, I will disconnect the cable behind the control head to stop the beeping!
Many thanks
--
Dean Gillies
SV Stella *****, Amel 54-154
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|
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Roque
Hi Dean
In addition to all previews comments:
1. Yes, the sensor is just a reed switch. While I was waiting for a replacement, I “fabricated” one using a reed switch inside a plastic tube (BIC pen). The reed switches cost US 1 a dozen. I still have the Lewmar new one in the box as a spare!
2. I would begin by replacing the magnet. Easy task, also inexpensive on Ebay.
3. I never found a conector along the wire but I suppose there is none. The wire is very unlikely to be the problem.
Roque Attika A-54 # 117 Paraty. Brazil
Hi Dean,
I replaced my non functioning Lewmar chain counter with the Lofrans version (Iris) a couple of years ago. Has been perfect ever since. I changed the sensor and the magnet. The sensor is mounted from below the windlass. I tried yanking the old one out by the wire but broke it. So I drilled it out. I then inserted the new one and sealed it in place with silicon.
I then spliced the new cables to old with solder and heat shrink tubing.
The magnet too, which is on the gypsy got drilled out and a new one epoxied in its place.
The whole installation up forward was pretty easy. The wiring above the galley sink was harder, from a dexterity point of view.
Nick S/Y Amelia AML54-019 Turkey Push the connector up it has the tendency to fall put some chewing gum or some plastic clay to keep it in place as much up as possible. The magnet in the gypsy is easy to inspect . It can be damaged from the salt and can easily been replaced if necessary. Do not turn the Gypsy upside down as the position of the magnet is different and you are going to have no signal at all
================= Στάλθηκε από το iPhone of Dimitris Krasopoulos Mob Greek +306944302318 Mob Dubai +971564602575 On Jun 3, 2022, at 9:28 AM, Dean Gillies <stella@...> wrote:
Hi Amelians,
I'm having a problem with the chain counter sensor of my Lewmar V4/5 windlass (Amel 54). The control head unit in the cockpit is the AA560. I assume this sensor is just a reed switch which triggers with each rotation of the gypsy as the magnet passes overhead.
The problem shows up as random counting (and beeping) and the diagnostic check shows the sensor output being "unstable". The voltages displaying on the AA560 diagnostic check are unstable, flickering between 4.8-5.0V on the red connection and 0-2V on the black connection.
So, it looks like I have either a faulty sensor or a problem in the wiring/connectors. I have checked the cable connections at the terminal block behind the AA560 head unit and they look fine.
In the fore-locker I can see the grey cable coming out of the windlass bottom plate where the sensor is located. The cable (along with the main power cabling for the windlass motor) then runs into some conduits and around into the switch panel in the box in the aft starboard corner of the fore-locker.
It seems to run through that locker (difficult to see) and out into a conduit that runs across the top of the locker and then aft into the boat.
The questions in my mind at the moment:
Is there a connector somewhere along this sensor cable run that could be faulty, or is it a single cable run from the sensor to the terminal block behind the control head?
Is it easy to remove that sensor from the windlass plate? How? Is it glued in there?
Has someone trodden this path before me and can offer some guidance?
In the meantime, I will disconnect the cable behind the control head to stop the beeping!
Many thanks
--
Dean Gillies
SV Stella *****, Amel 54-154
--
Roque
Attika A54 117
Paraty - Brazil
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Here are some pages from the manual that answer your questions and also a link to download the manual. I suspect that the connectors probably exist, but I do not know where. Also, note the "GREY" & "BLACK" sensors.
| | CW Bill Rouse Amel Owners Yacht School | | | 720 Winnie, Galveston Island, Texas 77550 | |
|
Hi Dean
In addition to all previews comments:
1. Yes, the sensor is just a reed switch. While I was waiting for a replacement, I “fabricated” one using a reed switch inside a plastic tube (BIC pen). The reed switches cost US 1 a dozen. I still have the Lewmar new one in the box as a spare!
2. I would begin by replacing the magnet. Easy task, also inexpensive on Ebay.
3. I never found a conector along the wire but I suppose there is none. The wire is very unlikely to be the problem.
Roque Attika A-54 # 117 Paraty. Brazil Hi Dean,
I replaced my non functioning Lewmar chain counter with the Lofrans version (Iris) a couple of years ago. Has been perfect ever since. I changed the sensor and the magnet. The sensor is mounted from below the windlass. I tried yanking the old one out by the wire but broke it. So I drilled it out. I then inserted the new one and sealed it in place with silicon.
I then spliced the new cables to old with solder and heat shrink tubing.
The magnet too, which is on the gypsy got drilled out and a new one epoxied in its place.
The whole installation up forward was pretty easy. The wiring above the galley sink was harder, from a dexterity point of view.
Nick S/Y Amelia AML54-019 Turkey Push the connector up it has the tendency to fall put some chewing gum or some plastic clay to keep it in place as much up as possible. The magnet in the gypsy is easy to inspect . It can be damaged from the salt and can easily been replaced if necessary. Do not turn the Gypsy upside down as the position of the magnet is different and you are going to have no signal at all
================= Στάλθηκε από το iPhone of Dimitris Krasopoulos Mob Greek +306944302318 Mob Dubai +971564602575 On Jun 3, 2022, at 9:28 AM, Dean Gillies <stella@...> wrote:
Hi Amelians,
I'm having a problem with the chain counter sensor of my Lewmar V4/5 windlass (Amel 54). The control head unit in the cockpit is the AA560. I assume this sensor is just a reed switch which triggers with each rotation of the gypsy as the magnet passes overhead.
The problem shows up as random counting (and beeping) and the diagnostic check shows the sensor output being "unstable". The voltages displaying on the AA560 diagnostic check are unstable, flickering between 4.8-5.0V on the red connection and 0-2V on the black connection.
So, it looks like I have either a faulty sensor or a problem in the wiring/connectors. I have checked the cable connections at the terminal block behind the AA560 head unit and they look fine.
In the fore-locker I can see the grey cable coming out of the windlass bottom plate where the sensor is located. The cable (along with the main power cabling for the windlass motor) then runs into some conduits and around into the switch panel in the box in the aft starboard corner of the fore-locker.
It seems to run through that locker (difficult to see) and out into a conduit that runs across the top of the locker and then aft into the boat.
The questions in my mind at the moment:
Is there a connector somewhere along this sensor cable run that could be faulty, or is it a single cable run from the sensor to the terminal block behind the control head?
Is it easy to remove that sensor from the windlass plate? How? Is it glued in there?
Has someone trodden this path before me and can offer some guidance?
In the meantime, I will disconnect the cable behind the control head to stop the beeping!
Many thanks
--
Dean Gillies
SV Stella *****, Amel 54-154
--
Roque
Attika A54 117
Paraty - Brazil
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Dean Gillies
This forum is amazing! So much knowledge and experience..
So, I will clean and check out the magnet and swap the gypsy from the secondary windlass too to see if that makes a difference. Also, I will check that the sensor has not slipped down. I can see it is about 3mm below the top surface, which seems ok according to Bill's table of distances. (It's a grey sensor)
The consensus seems to be that there is no connector in the cable-run, in which case the trouble is either with the sensor or magnet.
If I need to replace the sensor, it seems I can either drill out the old one or maybe knock it out with a 10mm dowel and mallet? The grey sensor kit comes with a magnet, so I will replace that too. Getting my hands on the sensor kit while cruising in Greece will be a little tricky.
Thank you Vladan, Dimitris, Nick, Roque and Bill. I have been helped up this little learning curve very quickly :-)
--
Dean Gillies
SV Stella *****, Amel 54-154
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Dean,
They have many shops in Greece and they can also deliver to you.
Best Regards,
Vladan
toggle quoted message
Show quoted text
From: main@AmelYachtOwners.groups.io <main@AmelYachtOwners.groups.io> on behalf of Dean Gillies <stella@...>
Sent: Friday, June 3, 2022 10:23:59 PM
To: main@AmelYachtOwners.groups.io <main@AmelYachtOwners.groups.io>
Subject: Re: [AmelYachtOwners] Chain Counter Sensor Connector A54
This forum is amazing! So much knowledge and experience..
So, I will clean and check out the magnet and swap the gypsy from the secondary windlass too to see if that makes a difference. Also, I will check that the sensor has not slipped down. I can see it is about 3mm below the top surface, which seems ok according
to Bill's table of distances. (It's a grey sensor)
The consensus seems to be that there is no connector in the cable-run, in which case the trouble is either with the sensor or magnet.
If I need to replace the sensor, it seems I can either drill out the old one or maybe knock it out with a 10mm dowel and mallet? The grey sensor kit comes with a magnet, so I will replace that too. Getting my hands on the sensor kit while cruising in Greece
will be a little tricky.
Thank you Vladan, Dimitris, Nick, Roque and Bill. I have been helped up this little learning curve very quickly :-)
--
Dean Gillies
SV Stella *****, Amel 54-154
-- Vladan A54 #157 SV PAME
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Roque
Dean
"I will clean and check out the magnet": It is the same work as just replacing it, so I would put a new one. I used neodymium magnet, less prone to oxidation, or so I was told. It is a regular industrial magnet widely available. If you can't find 10 x 8mm you can use 2 pieces 10 x 4. Just in case, measure the diameter of the hole before buying. By the way, you can use any magnet you have aboard to test the reed sensor manually.
"...drill out the old one or maybe knock it out with a 10mm dowel and mallet?": Mine easily got out just pushing and pulling. It was fixed with silicon.
"...swap the gypsy from the secondary windlass": check first if there is a hole already opened in the secondary one.
Good luck
Roque Em sex., 3 de jun. de 2022 às 16:56, Vladan SV PAME < vladan.bojic@...> escreveu:
Dean,
They have many shops in Greece and they can also deliver to you.
Best Regards,
Vladan
This forum is amazing! So much knowledge and experience..
So, I will clean and check out the magnet and swap the gypsy from the secondary windlass too to see if that makes a difference. Also, I will check that the sensor has not slipped down. I can see it is about 3mm below the top surface, which seems ok according
to Bill's table of distances. (It's a grey sensor)
The consensus seems to be that there is no connector in the cable-run, in which case the trouble is either with the sensor or magnet.
If I need to replace the sensor, it seems I can either drill out the old one or maybe knock it out with a 10mm dowel and mallet? The grey sensor kit comes with a magnet, so I will replace that too. Getting my hands on the sensor kit while cruising in Greece
will be a little tricky.
Thank you Vladan, Dimitris, Nick, Roque and Bill. I have been helped up this little learning curve very quickly :-)
--
Dean Gillies
SV Stella *****, Amel 54-154
--
Vladan
A54 #157
SV PAME
--
Roque
Attika A54 117
Paraty - Brazil
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Dean Gillies
Thanks Vladan, I have sent an email to the Lefkada store.
Roque,
Its not so easy to get my hands on a magnet while cruising in Greece, so I'll cough up for the kit!
The sensor works with a big magnet and I cleaned up both gypsies (grease) and it still works with both gypsies. There is a magnet in both gypsies.
The problem I observe is that it sometimes counts when the gypsy is not turning and the diagnostic test says "unstable sensor output". My suspicion is still a bad electrical connection (probably ground connection) either at the sensor or at the connector. I think the magnets are ok.
I Investigated a bit further this morning, and found that there must be a connector or joint in the wiring.
The cable coming from the sensor is 3.75mm diameter (see pic), it then runs into a horizontal conduit running to starboard on the roof of the locker. When it exits from that conduit on the starboard side (see other pic), the diameter has changed to 4.25mm. I suspected that it was different just by eye, and checked it with a gauge. There must be a joint or connector in that conduit.
So the fault remains the same .. either there is a bad joint inside that conduit or where the wire enters the sensor.
I will fit a new sensor (glad to hear it pushed out easily!) and I will pull the cable through that first conduit and make the new joint there, discarding the old joint too. I would prefer to make the new joint inside the electrical box on the stbd side, but the cable entry is sealed up so I don't want to disturb it. I'm not sure why Pochon didn't put the joint in there in the first place, maybe the sensor cable is too short.
On a positive note, after my tugging and fiddling with the sensor cable this morning, the random counts have now stopped. I can spin the gypsy and it counts cleanly, and there is no sign of the random counts. Definitely a suspect connection! I'm sure the problem will return with morse code-like beeps coming from the cockpit in the wee small hours.
Best regards to all
--
Dean Gillies
SV Stella *****, Amel 54-154
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Dean Gillies
Well, I managed to get my hands on a new sensor from George's Chandlery at Nidri, Lefkada. Great guy and an amazing Aladdin's Cave of a shop.
I removed the old sensor by pushing down on the top with an Allen Key. It dropped out fairly easily.
I was then able to uncover the joint in the original cable which is inside the conduit on the roof of the bow locker. I removed the heat-shrink sleeve and inspected the connections. No corrosion and the connections looked fine. I then removed the old sensor, joined the new sensor cabling in the same place with heat-shrink sleeving and tried to insert the new sensor into the windlass from the underside! Don't do that, it's too difficult!
I then cut the joint back out and inserted the sensor from the top, this was much much easier to do.
I made the joint again in the same place with heat-shrink sleeve and pushed the joint into the conduit.
I then ran the diagnostics and everything checked out ok. The system is now running reliably again.
I did not install the new magnet that came with the sensor, as everything is now working fine with the original magnet.
Thanks to all for the support, much appreciated.
Tomorrow's maintenance activity ... new timing belt 🙀
--
Dean Gillies
SV Stella *****, Amel 54-154
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