The complete guide to expanding, upgrading, surveying and troubleshooting your boat's AC and ...

145 Pages·2007·13.07 MB·English

The complete guide to expanding,
upgrading, surveying and
troubleshooting your boat’s
AC and DC electrical system.
CLICK HERE TO ENTER
888-658-boAT (2628)
E-mail: [email protected]
www.diy-boat.com
©2007 JM Publishing
contents
Systems
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Design a Trouble-Free Electrical System 4
Preparing a Wiring Schematic 12
Index of DIY articles Power Consumption Worksheet 16
DC System Upgrades 17
Circuit Protection Devices 25
Help
Fuses & Circuit Breakers 26
Fine Tuning DC Systems 30
Terms of Use Switches: Selection, Installation, Usage 33
Sample Switch Installations 36
Electrical Panel Selection & Installation 37
Disclaimer
Upgrading a ‘70s Cruiser 42
AC Power: Components & Troubleshooting 46
Quit
Hands-on Wiring
AC Wiring Tips 54
Wiring Tools & Techniques 55
Crimping 101 58
Wiring Basics 59
Boat Wire List 60
Wire Standards 61
Wire Color Codes 62
Engine Wiring Color Codes 63
Wire Identification 64
Formula for Sizing Conductors 65
Conductor Sizing and Voltage 66
7
Conductor Ratings 6
8
2
6 Batteries
2
58- Ratings, Performance & Efficiency 68
6
88- Selection & Sizing for House Loads 71
8
1- Selection, Installation, Maintenance 74
1
0
0 Battery Construction 78
2
er
n Calculating Battery Requirements 79
w
o
at
o
Y b (continues on next page)
DI
©
contents
(continued from previous page)
Subscribe to DIY Boat Owner
Reducing Electrical Demands 80
Easy-to-Make Battery Cables 83
Index of DIY articles 1995-2006 Batteries and Charging FAQ 84
Generating Power with Fuel Cells 87
Using Batteries to Produce AC Power 90
Help
Charging Issues
Terms of Use Solar, Wind and Water Power: Selection &
Installation 94
Solar Panel Mounting Solutions 97
Disclaimer
Charging Problems & Solutions 101
Inverter: Selection & Installation 103
Quit Gen-sets: Selection, Installation and Options 108
Battery Combiners & Isolators 112
Charge Controls for Charging Sources 115
High-Output Alternators 118
Upgrading an Alternator or Regulator 121
Troubleshooting
Using a Multimeter 125
Testing a Boat’s DC Bonding System 127
Diagnostic Troubleshooting 130
AC System Troubleshooting 132
Troubleshooting Electrical Circuits 136
Troubleshooting Engine Electrical Systems 137
Breaking the Ground Circuit 140
Design a Trouble-Free
ELECTRICAL SYSTEM
Are you contemplating a major overhaul of your boat's
Contents electrical system? Here's how to design an efficient trouble-
free DC system and the proper techniques for installing
electrical cables and circuits.
Next
By Kevin Jeffrey
Sample Circuits
Previous Ac ircuit is a path that, if followed DC marine electrical circuits fall into two
completely, leads back to the starting categories — main circuits and branch or
place. Here we are concerned with marine subsidiary circuits. Main circuits originate
electrical circuits that provide a reliable path from the batteries and provide current directly
for direct current (DC). While there are definite to large appliance loads or to distribution
rules to follow when wiring a new boat or points housing multiple branch circuits. While
rewiring an existing one, the DC portion the methods of routing and controlling these
of the electrical system can be set up in a circuits may vary, the wiring techniques for the
variety of ways. With some creative thinking, best safety and efficiency remain the same.
proper circuit components, and good wiring Shown in Figures 1 and 2 are three
techniques, you can take the best advantage sample schematics depicting main and branch
of battery-supplied electricity on board. DC circuits commonly found on boats. Keep in
mind that components in a DC system can be
In DC circuits an electrical potential, or
arranged in a variety of ways.
voltage, drives the electrical current. Charging
sources create the necessary voltage to
Codes for Conductors
drive current into the batteries and, in turn,
Wire conductors carry the current from the
the batteries serve as a voltage source for voltage source to the loads. Other circuit
operating all DC loads on board, including components to consider include connectors to
inverters that, in turn, provide AC power. join conductors to electrical equipment or two
A boat has both charging circuits and load or more wires together, distribution posts or
circuits, yet all DC circuits must include busbars to conveniently join groups of positive
or negative wires, manual or automatic
the batteries. Individual batteries can be
switches to control current flow, diodes to
connected in a variety of ways to give you the
prevent reverse current flow, and meters and
system voltage and total battery capacity you
monitors to help make electricity visible.
require for house loads and engine starting
Wire conductors provide the supply and
(see Figures 1 and 2 for sample schematics return path from the voltage source to the
and refer to pages 68, 72 and page 73 for various electrical loads. DC wiring is selected
setting up batteries). for the type of job it must do, and is sized
A DC system has a positive and according to how much current it's expected
negative side to each circuit. The positive to safely carry and the allowable voltage drop
over its length of run. Conductors from 8 AWG
side originates at the positive terminal of
(American Wire Gauge) to /0 AWG, usually
the voltage source and goes to the positive
referred to as cable, is used for positive and
distribution point (if provided), then on to
negative conductors where high current is
individual loads. The negative side of the
expected, such as battery banks, large high-
circuit provides a return path back to the
output alternators, starter motors, and large
voltage source. The flow of electricity is inverters and chargers. Marine cable should
determined by the electrical resistance of the meet the same standards as other conductors
loads. For example, engine starters, freezers on board.
and large inverters have relatively little Wire and cable conductors are insulated
888-658-boAT (2628) for safety and should be installed to make
electrical resistance compared to lights and
E-mail: [email protected] certain electricity stays in its intended path. If
navigation instruments and, therefore, allow
www.diy-boat.com the electrical load is bypassed due to an
much more current to flow.
(continued on page 6)
©DIY Boat Owner 2007

C or.
d h, Donit
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CNPoreenxvttieonutss 10 9 11Main DCDistribution Panel 12Running Lights Instruments14 Cabin Lights VHF Other House Loads 15 13 TYPICAL WIRING INSTALLATIONInboard engine with single alternator, separate startinhouse battery banks with automatic battery parallel selectrical panel, separate bilge pump circuit and syste
er
6 4 AnchorWinch Invert
3
6
1
8
7
5 nator
Alter
3 ain DC egative Busbar VoltageRegulator BilgePump Battery Charger 17
MN 8
1 9
2 arter 1
nt St
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System Monitor 6 Volt 6 Volt attery arallel witch 12 Volt 20
BPS
E-m88a8il-:6 in5f8o-@bodAiyT- b(2o6a2t.8co)m 22 1 21 Battery Terminal Boots400 amp Fuse BlockBattery Switch On/OffCable ClampsPosi-Lock Butt ConnectorSplit Loom 150 amp Common Busbar250 amp MEGA FuseRing Terminal with Adhesive- Lined Heat-Shrink TubingCrimp-on Heat-shrink Ring TerminalButt ConnectorDisconnectWater Block AdhesivePressure ConnectorCircuit Breaker Panel100 amp MEGA FuseSpiral WrapBilge Pump WireOil-resistant WirePower PostBattery Cable Lugs100 amp Common Busbar
www.diy-boat.com 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1819 20 21 22
yrDneH eIrAM-ennA
©DIY Boat Owner 2007

2
Voltmeter
72” max
Panel for unswitched
loads such as
+
bilge pump
Fuse
1
Contents
2
Next
Battery Switch
Fuse
+
Charge
Previous control 7” - 40” rule
Solar panel
Distribution
Outboard
panel
engine
alternator
3-12V Main
batteries System monitor distribution
wired in panel
parallel Shunt Main DC negative +
busbar
Anchor
Sub winch
panel
12V On/Off battery
isolation switch To loads
12V
+
Inverter
12V Voltage Refrigerator
regulator
Battery
parallel
Bilge pumps Alt. 1
switch
+
Solar
1 Panel
12V Alt. 2 ry
Starter 1 D
n
Battery He
2 12V charger rIe
Starter 2 MA
Engine starting ne-
n
A
SAMPLE BOAT SCHEMATICS (Top) (Bottom): Dual inboard engines with
Single engine with alternator, two alternators, two starting and one house
batteries with manual battery switch, battery bank with automatic parallel
simple DC electrical panel, separate switch, multiple renewable charging
bilge pump circuit, voltmeter (battery sources, DC electrical panel, separate
condition meter) and solar panel. dual bilge pump circuits, system monitor,
inverter, anchor winch and refrigeration.
accidental "short" circuit, resulting high as the individual components and connections.
current can cause serious damage and Selecting the proper conductor type and size is
possibly a fire unless proper current a good place to start. even though high-quality
888-658-boAT (2628) protection devices — fuses (Figure 1, #8) conductors made to AWG standards are more
E-mail: [email protected] and circuit breakers — for each circuit are in expensive for a given size, they can actually
www.diy-boat.com place. save you money over the long term. AWG
The integrity of a DC circuit is only as good wires are up to 12% larger than the same
©DIY Boat Owner 2007
6
size SAe wire used for "surface vehicles," so runs require larger wire size. Conductors used
in many applications a smaller gauge AWG for electronic equipment, navigation lights or
wire can stay within the voltage drop limits other circuits where voltage drop should be
recommended by American Boat & yacht kept to a minimum shall be sized for a voltage
Council (AByC) and other marine standards drop not to exceed 3% (Table B on page 7).
(Tables B and C on page 8). Conductors used for general lighting and other
Wire conductors in a marine installation circuits where voltage drop is not critical may
face harsh conditions, and must adhere to the be sized for a voltage drop of 10% (Table C
Contents
following criteria: on page 8).
1. AByC standards state that "Conductors 6. There should be a means to easily
shall be at least 16 AWG (except 18 AWG may identify a conductor's function in an electrical
Next be used as internal wiring in panelboards), and system.
shall have a minimum rating of 0 volts." What to look for: Table E on page 10
2. Wire with multiple strands (Table shows the recommended color code for
Previous D on page 8 has a better ability to cope DC conductors used for general, engine
with repeated flexing without breaking, and and accessory wiring purposes on boats.
it makes for a much more reliable crimp AByC standards state "Color coding may
connection since the strands mold more be accomplished by colored sleeving (i.e.
completely to the terminal barrel. Solid wire colored heat shrink tubing) or color application
or wire with only Type 1 stranding is not (such as colored plastic tape) to wiring at
recommended for marine use. AByC standards termination points."
state that "Conductors with at least Type 2
stranding shall be used for general purpose Getting Connected
boat wiring. Conductors with Type 3 stranding Wire connectors come in a variety of designs
(many more strands per wire size) shall be as shown in Figure 1 on page 5. Solderless
used for any wiring where frequent flexing is crimp-on ring (#10) and captive spade
involved in normal use." Also look for wire terminals are the most commonly used
with tinned copper strands, since it offers the terminals, but they must be installed properly
maximum protection against corrosion and (See “Wiring runs and Connections” on page
electrolysis. 6). It's important to realize that crimping
3. The wire insulation should be able to is a system, in which the wire, connector,
withstand the maximum ambient conditions: crimping tool and installation technique
temperature; moisture; contact with saltwater, must be matched to create a good electrical
oil, boat fuel, battery acid or other chemicals; connection.
exposure to sunlight. Other accepted terminals include friction
What to look for: A commonly available connectors (#5, #12) — male and female
conductor such as UL 126 boat cable meets components that pull apart — and pressure
most ambient conditions found on board connectors (#14) — wires are joined and held
(Figure 1, #19). together with pressure from a bolt or set screw
4. The ampacity (ability to carry current) — provided these types of connectors meet
of the conductor and its insulation should be certain standards outlined below.
sufficient to avoid overheating. The ampacity Crimp-on butt connectors (#11) are
rating is independent of conductor length of available if needed to splice two conductors
run and voltage drop. in the middle of a wire run. Some controls
What to look for: refer to Table D and monitoring devices are supplied with wire
ampacity ratings for marine conductors under pigtails; for this gear you'll need to use crimp-
0 volts. These values are the safe amperages on butt connectors, or friction connectors that
which the conductor can carry on a continuous allow for easy disconnect and removal.
basis. They do not apply to intermittent Wire connectors are available as: 1)
starting loads such as motor start currents. non-insulated, 2) with an insulated barrel,
Wiring in and passing through engine spaces 3) with an insulated barrel with additional
must be able to operate at higher ambient insulation grip (on connectors made to be
temperatures. double-crimped — one crimp on the barrel for
5. The wire should be of sufficient size so electrical contact and one on the insulation for
that the voltage drop over the length of run not added strain relief), and ) as fully insulated
impair the load's ability to function. disconnects (when connected, no bare metal
888-658-boAT (2628)
What to look for: Voltage drop is a is visible).
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function of expected amperage (current) and Terminals for connecting battery cable
www.diy-boat.com length of run; increased amperage and longer from 8 AWG to /0 AWG are available as
©DIY Boat Owner 2007 (continued on page 9)
7
tABLe B: AWG COnDuCtOr SIZeS FOr 3% VOLtAGe DrOP At 12 VOLtS
Current (amps)**
5 10 15 20 25 30 40 50 60 70 80 90 100
10' 18 1 12 12 10 10 8 8 6 6 6  
1' 16 12 10 10 8 8 6 6    2 2
*
Contents h 20' 1 12 10 8 8 6 6    2 2 2
t
G
n 2' 1 10 8 8 6 6   2 2 2 1 1
e
L 30' 12 10 8 6 6   2 2 2 1 1/0 1/0
Next
0' 12 8 6 6   2 2 1 1/0 1/0 2/0 2/0
0' 10 8 6   2 2 1 1/0 1/0 2/0 3/0 3/0
Previous 60' 10 6 6  2 2 1 1/0 2/0 2/0 3/0 3/0 /0
70' 10 6  2 2 2 1/0 2/0 2/0 3/0 3/0 /0 /0
80' 8 6  2 2 1 1/0 2/0 3/0 3/0 /0
90' 8   2 1 1/0 2/0 3/0 3/0 /0
100' 8  2 2 1 1/0 2/0 3/0 /0 /0
Use this table for any critical applications: bilge pumps, navigation lights, electronic, etc.
The next larger conductor should be used when length falls between two conductor sizes.
For determining conductor size in 24-volt and 32-volt systems see "Formula For Sizing
Conductors" on page 65. e
n
*Length of wire from the positive power source (battery, panelboard or switchboard) to ArI
M
electrical device and back to the negative power source in feet. Or
C
** Total current on circuit in amps. Where there is a variance between the voltage drop and An
e:
the ampacity (Table D on page 9), use the larger wire size. rC
U
O
S
tABLe C: AWG COnDuCtOr SIZeS FOr 10% VOLtAGe DrOP At 12 VOLtS
Current (amps)**
5 10 15 20 25 30 40 50 60 70 80 90 100
10' 18 18 18 16 16 1 1 12 10 8 8 6 6
1' 18 18 16 16 1 1 12 12 10 8 8 6 6
*
h 20' 18 16 16 1 12 12 10 10 8 8 8 6 6
t
G 2' 18 16 1 12 12 10 10 8 8 8 6 6 6
n
e 30' 18 16 1 12 10 10 8 8 8 6 6 6 
L
0' 16 1 12 10 10 8 8 6 6 6   
0' 16 12 10 10 8 8 6 6     2
60' 16 12 10 8 8 8 6    2 2 2
70' 1 12 10 8 8 6 6   2 2 2 2
80' 1 10 8 8 6 6   2 2 2 2 1
90' 1 10 8 8 6 6   2 2 2 1 1
100' 12 10 8 6 6   2 2 2 1 1 1/0
Use this table for any non-critical applications: cabin lights, stereo, etc. The next
larger conductor should be used when length falls between two conductor sizes. For
determining conductor size in 24-volt and 32-volt systems see "Formula For Sizing e
n
Conductors" on page 65. ArI
M
*Length of wire from the battery to electrical equipment and back in feet. Or
C
** Total current on circuit in amps. Where there is a variance between the voltage An
888-658-boAT (2628) drop and the ampacity (Table D on page 8), use the larger wire size. rCe:
U
O
E-mail: [email protected] S
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©DIY Boat Owner 2007
8
heavy-duty lugs (#21), similar to ring terminals equipment termination points, instead of
used for smaller wire, and heavy-duty butt joining conductors in the middle of a run —
connectors. For heavy-duty applications, lugs additional connections increase the potential
are available with a thicker wall for higher for problems down the road. Convenient
strength and less heat, a wider pad for better termination points are found at batteries,
contact and a longer barrel for more crimp distribution posts and blocks, electric panels
area. (Figure 1, #15), loads, switches, controls and
Protective sleeves that insulate the other devices in the circuit.
Contents
metal shank of terminal connections are Battery switches isolate the batteries from
recommended. The best way to comply is the charging sources or electrical loads, but
to use short sections of adhesive-lined heat- they can also serve as a convenient power
Next shrink tubing. When heated they form a tight, distribution point. For example, on systems
tABLe D: COnDuCtOr rAtInGS
Previous
AWG AWG Minimum Ampacity in
3
CM number of engine Space
Strands
1 2
TyPe 2 TyPe 3 OUTSIDe InSIDe

18 1,600 16 — 20 17
16 2,600 19 26 2 21
1 ,100 19 1 3 31
12 6,00 19 6  38
10 10,00 19 10 60 1
8 16,800 19 168 80 68
6 26,600 37 266 120 102
 2,000 9 20 160 136
2 66,00 127 66 210 178
1 83,690 127 836 2 208
0 10,600 127 106 28 22
2/0 133,100 127 1323 330 280
3/0 167,800 29 1666 38 327
/0 211,600 18 2107  378
1
Conductors with Type 2 stranding used for general purpose boat wiring.
2 Conductors with Type 3 stranding used where frequent flexing occurs. ByC
A
3 Ampacity values for cables in circuits under 50 volts based on an ambient temperature 98
9
1
of 50°C (122°F) and are independent of conductor length of run. See Tables B and C for e:
C
r
specifics. Where there is a variance, use the larger wire size. U
O
S
moisture-resistant seal over the terminal with a separate engine starting bank and a
shank. not only do adhesive-lined sleeves simple On/OFF disconnect switch (Figure
seal out moisture, they also provide additional 1, #3) for a single house bank the switch
strain relief between connector and wire. terminal closest to the positive post of the
Terminals from 22 AWG to 10 AWG with batteries can be used for connecting the
preformed adhesive-lined heat-shrink are positive leads of bilge pumps and renewable
also available, making installation convenient chargers that you don't want to accidentally
for the DIyer. In areas where moisture is disconnect with the other loads. For systems
a concern, seal multiple wires with Water with dual battery banks for either house loads
Block Adhesive (#13) from Ancor Marine, or engine starting (Figure 2, top), the common
a combination of heat-shrink adhesive with positive terminal on a 1-2-BOTH-OFF switch
preformed wire channels and a clear outer can be used to connect the positive feeds to
888-658-boAT (2628)
section of heat-shrink tubing. the starter circuit and the load distribution
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panel, as well as the positive leads from
www.diy-boat.com Power Distribution Points renewable chargers.
It's best to make all wiring connections at Multiple conductors can be joined in a
©DIY Boat Owner 2007
9
tABLe e: SAMPLe WIre COLOr CODe
COLOr IteM WIre uSe
Black or yellow Ground negative mains
Blue, dark Cabin & instrument lights Fuse or switch to lights
Blue, light Oil pressure Oil pressure sender to
Contents gauge
Brown w/yellow Bilge blowers Fuse or switch
stripe or yellow* to blowers
Next
Gray, dark navigation lights Fuse or switch to lights
Tachometer Tachometer sender to
gauge
Previous
Green or green Bonding systems Grounding conductors
w/yellow stripe
Brown Generator armature Generator armature to
regulator
Alternator charge light Generator terminal
or alternator
Auxiliary terminal to
regulator
Pumps Fuse or switch to pumps
Orange Accessory feed Ammeter to alternator or
generator output and
accessory fuses or
switches
Pink Fuel gauge Fuel gauge sender to
gauge
Purple Ignition Ignition switch to coil and
electrical instruments
Instrument feed Distribution panel to
electric instruments
red Main power feeds Positive Conductors
Tan Water temperature Water temperature
sender to gauge
C
By
yellow w/ Starting circuit Starting switch to 8 A
9
red stripe solenoid 19
e
C
r
*If yellow is used for negative, blower must be brown with yellow stripe. OU
S
circuit by using a power distribution post, Make sure that all branch circuits on board
busbar or splicer block. Distribution posts are are protected with appropriately sized fuses
used for large battery cable to branch out from (Figure 1, #16) or circuit breakers.
a central positive connection, or to consolidate Most branch load circuits on a boat are
a number of negative return cables, allowing connected inside a DC distribution panel.
you to take one large cable to the engine Marine panels typically have a positive busbar
block. These posts are available with 1/", and disconnects, and fuses or circuit breakers
/16" or 3/8" diameter studs Figure 1, #20). for each branch, and may also include
Busbars (Figure 1, #7) and splicer blocks additional circuit switching or monitoring
perform the same function as distribution functions.
posts, only they offer multiple connection
888-658-boAT (2628)
points. Branch circuits for large loads, such Setting Up The Circuits
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as windlass, large inverter, or refrigeration are First, create a rough system schematic of how
www.diy-boat.com often distributed through a separate heavy- the electrical components and circuits will be
duty busbar as shown in Figure 2, bottom.
©DIY Boat Owner 2007
10