Josh is an idiot. Umm...what part of the wire is severely undersized did you not understand??
For a high-load device like this, you want a maximum of 3% voltage drop, preferably less.... You really want to oversize the wire a bit to allow for the eventual increase in resistance that happens with most wiring as it ages. Maine Sail, Mitiempo and I all are recommending that you go with 4/0 wire for a reason.
The greater the voltage drop, the higher the amperage the motor will draw, and the more likely the motor is to burn out. Using 2 AWG wire for that run will lead to a 5.7% voltage drop under ideal conditions. Once the wire and terminals start getting older, you'll see a bigger drop than that.
From the Lewmar Horizon 400 manual:
Check the voltage across the motor leads with the windlass on. (Proper voltage is 13.5 volts. Constant low voltage will destroy the motor).
Is the voltage low? (Below 11.0 volts on a 12 volt system).
By using 2 AWG wire, you’re pretty much guaranteeing that this will be a recurring issue for your windlass.
OK I called (finally found the support #) Lewmar and talked to Josh who said I should use 2 AWG wire for the 25’ run. That seems about right I am guessing.
H3 12v windlass
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