CH 2 Wiring Slides 042909

Chapter 2
Electrical Wiring Practices and Diagrams
MElec-Ch2 - 1
Overview
Safety Standards Wiring Considerations Wire Terminations Coaxial Cable Wiring Installations Wiring Diagrams
MElec-Ch2 - 2
Safety
Lethal Current
Safety Precautions
MElec-Ch2 - 3
Lethal Current
Fundamental policy of the USPS is SAFETY Human Body
Resistance 4 K (moist skin) to 24 K (dry skin) Safe current (through chest) less than 20 milliamps E = 120 VAC R = 4 K I = 30 milliamps - NOT SAFE I=?
Dont want current through chest cavity (may be lethal)
MElec-Ch2 - 4
Safety Precautions
Turn circuit off
Disconnect service cord Disconnect negative battery cable
If must work on live AC circuit

Need 2nd safety person
Remove metal jewelry
Know your boat and its wiring

Use outlet tester on AC outlets
Use 3-wire extension cord from GFI outlet

MElec-Ch2 - 5
Standards
American Boat and Yacht Council (ABYC)
AC and DC Electrical Systems is E-11 Minimum standards
Construction Repair
Marine Dept. of Underwriters Laboratory

Test and certify commercial products Safety, not function
MElec-Ch2 - 6
Wiring Considerations
Conductors Wire Types
Wire Size Wire Insulation

Wire Color Code
MElec-Ch2 - 7
Conductors
Connects power sources to power loads Characteristics
Safe Dependable Efficient (minimal voltage drop)
Boat environment
Worse than either house or car High humidity Vibration Corrosive conditions
MElec-Ch2 - 8
Wire Types
Marine Grade
Type 3 is recommended
Stranded copper
Tinned is preferred
MElec-Ch2 - 9
Wire Size
3% voltage drop
Critical circuits (Nav lights) Electronic Equipment
10% voltage drop

Cabin lights Motorized Equipment
Minimum size AWG # 16

MElec-Ch2 - 10
Wire Has Resistance

12 VDC
0.1 0.1
10A
What Voltage?
An. 10 VDC
Inadvertent Resistors
Wire too small (min of #16 - properly size using table) Bad connections (or corroded connections)
Clean and tighten battery connectors Tighten lug screws and inspect wire to lug connection
Why do wires get warm / hot?

Low resistance circuits pass high current (P = I2 x R) Wires can account for much of the overall resistance
MElec-Ch2 - 11
Wire Size Comparison
#16 top to #10 bottom #2 top to #10 bottom
MElec-Ch2 - 12
Copper Wire Characteristics
MElec-Ch2 - 13
12- VDC Wire Size Selection
MElec-Ch2 - 14
12 VDC Wire Size Selection
MElec-Ch2 - 15
120 VAC Wire Size Selection
MElec-Ch2 - 16
What Size Wires?
MElec-Ch2 - 17
Step 1
B
What current to Load?
I = 10 Amps
P = E * I I = P / E I = 1200/120 From Table 2-1 For 10A need #16 wire From Table 2-3 Maximum of 44 feet (for 10A in #16 wire)
MElec-Ch2 - 18
Step 1 Answers
AMPACITY 10 Amperes #16 AWG TW by Table 2-1
B
for 3% voltage drop 44 feet maximum by Table 2-3

MElec-Ch2 - 19
Step 2
B
What current to Inverter? Iload = 100 Amps @ 12 V Iload = Iout = Iin *0.91 Iin = Iout / 0.91 = 100 / 0.91 = 110 Amps From Table 2-1 For 110A need #1 wire From Table 2-3 Maximum of 14 feet (for 110A in #1 wire)
MElec-Ch2 - 20
Step 2 Answers
AMPACITY 110 Amperes #1 AWG TW by Table 1
B
for 3% voltage drop 14 feet maximum by Table 2-2A

MElec-Ch2 - 21
Wire Insulation
AC cables must be type UL 1426 BC
600 volt insulation Gasoline and Oil resistant Wont absorb moisture
DC wires & cables must be Marine Grade

600 volt insulation Gasoline and Oil resistant Wont absorb moisture
Color coded wires

MElec-Ch2 - 22
Wire Color Code

Color AC
(Hot)
AC
(Neut)
AC
(Gnd)
DC +
DC -
Black X White X Green (may have a yellow stripe) Red X2 Yellow
X1
X X X1
Footnotes: 1 Yellow preferred for DC negative to avoid confusion with AC Hot wire 2 2nd hot wire in 220 VAC is Red
MElec-Ch2 - 23
Wire Color Coding
MElec-Ch2 - 24
Wire Terminations
Crimping
Special Tool Approved Marine Connectors Use of Ratcheting Tool
Solder Heat-shrink Tubing
MElec-Ch2 - 25
Wire Terminals
MElec-Ch2 - 26
Ratcheting Crimper
YES
NO
MElec-Ch2 - 27
Ratcheting Tool Use

First select appropriate connector Strip insulation length of stem plus 1/16 Insert stripped end all way into terminal
End should extend 1/16
Place terminal in same color slot

First crimp end of terminal barrel nearest ring Then crimp wire end of terminal barrel
Check the connection with a solid tug

MElec-Ch2 - 28
Soldering
Terminal connection cant be only soldered
Must also be crimped
Soldering is normally not required

Crimped connectors are acceptable to ABYC If solder, apply only to ring end of terminal
Solder changes stranded wire into solid

Stranded wire is flexible
Use 40% lead / 60% tin, rosin core solder

Battery lugs may be only soldered
MElec-Ch2 - 29
Heat-Shrink Tubing
Application Steps
MElec-Ch2 - 30
Coaxial Cable
Antenna cable Radio coax is 50 ohm with PL-259 Radio cable is cut to length Want attenuation under 3 db
TV cable is 75 ohm with F connectors
GPS cable is not cut to length

Coil excess in 1-foot loops
MElec-Ch2 - 31
Coaxial Cable Information
MElec-Ch2 - 32
Soldering PL-259 Connector
MElec-Ch2 - 33
Wiring Installation
Basic Considerations Distribution Panel Fuses / Circuit Breakers Branch Circuits
Wire Outlets Switches
Grounding Systems Bonding Systems

MElec-Ch2 - 34
Basic Considerations
Must have source and return wires
Return wires to a common point May use feeder wire from power panel for:
engine, helm console, etc.
Wires above flood level of bilge

Waterproof if in bilge
Insulated support every 18 Twist DC wires within 1 meter of compass
MElec-Ch2 - 35
Distribution Panel
Central location of Circuit Breakers / Fuses
All branch circuits from this location
AC and DC may be combined in one panel
All equipment / circuits should go to panel

Not direct to battery (except bilge pump)
Noise interference suppression covered in Section 7
MElec-Ch2 - 36
DC / AC Power Panel
Front View
MElec-Ch2 - 37
Inside Power Panel
Buss Bars
DC Side
MElec-Ch2 - 38
Fuses and Circuit Breakers

Used to protect wiring from over current
In positive or hot wire
Newer boats use circuit breakers

Initially more expensive
Replace blown fuse with correct rating

Circuit Breakers should be Marine Grade
Trip free Manual reset
MElec-Ch2 - 39
Branch Circuits - Wires

Minimum size is 16 AWG
See Wire Selection Tables For AC normally #14 for 15A and #12 for 20A
Must terminate in closed electrical box

Of sufficient length DC negative returned to DC Panel
May use several negative feeder terminals
AC neutrals returned to AC Panel
Bonding system never used as return wire

MElec-Ch2 - 40
Branch Circuits - Outlets

120 VAC outlets must be 3-wire polarized
Black (hot) to brass or copper colored terminal
Outlet wires must have crimp terminals GFI outlets

Required on weather deck, head, galley and machinery spaces Good practice for all AC outlets to be GFI Trip at 5 milliamps
Different outlets for AC and DC power

MElec-Ch2 - 41
Outlets and Plugs

12 VDC 120 VAC 120 VAC 120 VAC
DC Outlet (Receptacle)
15 A Outlet
GFI 15 A Outlet
20 A Outlet
DC Plug
AC Plug 15 A
AC Plug 20 A
MElec-Ch2 - 42
Branch Circuits - Switches

Modern panels use Circuit Breakers
Which also double as switches
Switches / Circuit Breakers

Must be Marine Grade Rated for the voltage and current controlled Interrupt the positive (DC) or hot (AC) leg
Battery Switch
Designed for high current service Not located in engine or fuel-tank compartments
MElec-Ch2 - 43
Grounding System
Ground is potential of water around boat
Or potential of earths surface
DC Ground Battery negative terminal(s)

Also engine block Wire color is Yellow (or Black)
AC Transformer center tap on shore

Also connected to ground rod at transformer Wire color is Green and uninterrupted wire
Isolation transformers and galvanic isolators are exception and covered in Chapter 4 on AC
Engine, DC negative & AC ground connected

MElec-Ch2 - 44
Bonding System
For lightning protection
More in Chapter 6
All metal objects should be bonded

Keeps all metal at zero potential Engine blocks Battery negative terminals
Non-current carrying wire Through-hull fittings
ABYC now recommends they be bonded Electrically isolated from metal hull
MElec-Ch2 - 45
Bonding Diagram
MElec-Ch2 - 46
Wiring Diagrams
Elements of a Good Wiring Diagram
Documents boats electrical layout Should be kept current Used for troubleshooting
Component Identification
Physical objects to their symbol Wires are color coded
MElec-Ch2 - 47
Wiring Diagram Symbols

Wire (insulated, metal conductor) Incandescent Light
Wires crossing (but NOT connected)
Alternate symbol for Light
Wires connected (at dots)
Circuit Breaker
Battery (long line on top is positive)
Fuse
Switch, single pole, single throw (SPST)
Ground
Switch, single pole, double throw (SPDT)
Male Connector
Switch, double pole, single throw (DPST)
Female Connector
MElec-Ch2 - 48
Simple DC Wiring Diagram
MElec-Ch2 - 49
Summary
Circuits should be off when working on them
Use only marine grade properly sized wires

Tables will help determine proper wire size Minimum wire size is #16 AWG
Use wire terminations and ratcheting crimper DC circuits are 2 dedicated wires
Waterproof wire connection in bilge
AC circuits are 3 dedicated wires
GFCI in galley, head, machine spaces & weather deck
Separate Grounding & Bonding systems required Keep wiring diagram current
MElec-Ch2 - 50

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Chapter 2

Electrical Wiring Practices and Diagrams

Dont want current through chest cavity (may be lethal)

If must work on live AC circuit

Remove metal jewelry

Know your boat and its wiring

Use 3-wire extension cord from GFI outlet

Marine Dept. of Underwriters Laboratory

Wire Size Wire Insulation

10% voltage drop

Minimum size AWG # 16

Wire Has Resistance

Why do wires get warm / hot?

Wire Size Comparison

#16 top to #10 bottom #2 top to #10 bottom

Copper Wire Characteristics

12- VDC Wire Size Selection

12 VDC Wire Size Selection

120 VAC Wire Size Selection

What Size Wires?

What current to Load?

for 3% voltage drop 44 feet maximum by Table 2-3

for 3% voltage drop 14 feet maximum by Table 2-2A

DC wires & cables must be Marine Grade

Color coded wires

Wire Color Code

Black X White X Green (may have a yellow stripe) Red X2 Yellow

Wire Color Coding

Solder Heat-shrink Tubing

Ratcheting Tool Use

Place terminal in same color slot

Check the connection with a solid tug

Soldering is normally not required

Solder changes stranded wire into solid

Use 40% lead / 60% tin, rosin core solder

TV cable is 75 ohm with F connectors

GPS cable is not cut to length

Coaxial Cable Information

Soldering PL-259 Connector

Grounding Systems Bonding Systems

Wires above flood level of bilge

Insulated support every 18 Twist DC wires within 1 meter of compass

AC and DC may be combined in one panel

All equipment / circuits should go to panel

Inside Power Panel

Fuses and Circuit Breakers

Newer boats use circuit breakers

Replace blown fuse with correct rating

Branch Circuits - Wires

Must terminate in closed electrical box

AC neutrals returned to AC Panel

Bonding system never used as return wire

Branch Circuits - Outlets

Outlet wires must have crimp terminals GFI outlets

Different outlets for AC and DC power

Outlets and Plugs

Branch Circuits - Switches

Switches / Circuit Breakers