Chapter 2 Electrical Wiring Practices and Diagrams MElec-Ch2 – 1

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 KΩ (moist skin) to 24 KΩ (dry skin) Safe current (through chest) – less than 20 milliamps E 120 VAC R 4 KΩ I 30 milliamps - NOT SAFE I ? Don’t 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 Ώ 0.1 Ώ 10A V 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 I 2 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? B 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 Won’t absorb moisture DC wires & cables must be Marine Grade 600 volt insulation Gasoline and Oil resistant Won’t absorb moisture Color coded wires MElec-Ch2 - 22

Wire Color Code Color AC (Hot) AC (Neut) Black X X1 White X Green (may have a yellow stripe) Red X2 X Yellow X1 AC (Gnd) DC DC - X 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 can’t 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 DC Outlet (Receptacle 15 A Outlet ) DC Plug 120 VAC 120 VAC GFI 15 A Outlet 20 A Outlet AC Plug 15 AC Plug 20 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 earth’s 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 boat’s 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) Switch, single pole, single throw (SPST) Switch, single pole, double throw (SPDT) Switch, double pole, single throw (DPST) Fuse Ground Male Connector 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