Chapter 2 Chapter 2 Electrical Wiring Practices and Diagrams MEl ec- Ch2 - 1
Chapter 2Chapter 2
Electrical Wiring Practicesand Diagrams
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OverviewOverviewSafetyStandardsWiring ConsiderationsWire TerminationsCoaxial CableWiring InstallationsWiring Diagrams
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SafetySafetyLethal Current
Safety Precautions
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Lethal CurrentLethal CurrentFundamental 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 = ? I = 30 milliamps - NOT SAFE
Don’t want current through chest cavity (may be lethal)
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Safety PrecautionsSafety PrecautionsTurn circuit off
Disconnect service cordDisconnect negative battery cable
If must work on live AC circuitNeed 2nd safety person
Remove metal jewelryKnow your boat and its wiringUse outlet tester on AC outletsUse 3-wire extension cord from GFI
outletMElec-Ch2 - 5
StandardsStandardsAmerican Boat and Yacht Council
(ABYC)AC and DC Electrical Systems is E-11Minimum standards
Construction Repair
Marine Dept. of Underwriters LaboratoryTest and certify commercial productsSafety, not function
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Wiring ConsiderationsWiring ConsiderationsConductors
Wire Types
Wire Size
Wire Insulation
Wire Color Code MElec-Ch2 - 7
ConductorsConductorsConnects power sources to power
loadsCharacteristics
SafeDependableEfficient (minimal voltage drop)
Boat environmentWorse than either house or carHigh humidityVibrationCorrosive conditions
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Wire TypesWire Types
Marine GradeType 3 is recommended
Stranded copperTinned is preferred
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Wire SizeWire Size3% voltage drop
Critical circuits (Nav lights)Electronic Equipment
10% voltage dropCabin lightsMotorized Equipment
Minimum size AWG # 16MElec-Ch2 - 10
Wire Has ResistanceWire Has Resistance
Inadvertent ResistorsWire 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 MEl
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V12 VDC0.1 Ώ
0.1 Ώ10A What Voltage?
An. 10 VDC
Wire Size ComparisonWire Size Comparison
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#16 top to #10 bottom
#2 top to #10 bottom
Copper Wire Copper Wire CharacteristicsCharacteristics
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12- VDC Wire Size 12- VDC Wire Size SelectionSelection
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12 VDC Wire Size 12 VDC Wire Size SelectionSelection
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120 VAC Wire Size 120 VAC Wire Size SelectionSelection
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What Size Wires?What Size Wires?
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B
Step 1Step 1
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What current to Load?
From Table 2-3 – Maximum of 44 feet (for 10A in #16 wire)
P = E * I I = P / E I = 1200/120
I = 10 Amps
From Table 2-1 – For 10A need #16 wire
B
Step 1 AnswersStep 1 Answers
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AMPACITY10 Amperes
#16 AWG TWby Table 2-1
for 3% voltage drop44 feet maximum
by Table 2-3
B
Step 2Step 2
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What current to Inverter?
From Table 2-3 – Maximum of 14 feet (for 110A in #1 wire)
Iload = Iout = Iin *0.91 Iin = Iout / 0.91 = 100 / 0.91 = 110 Amps
From Table 2-1 – For 110A need #1 wire
B
Iload = 100 Amps @ 12 V
Step 2 AnswersStep 2 Answers
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AMPACITY110 Amperes#1 AWG TWby Table 1
for 3% voltage drop14 feet maximum
by Table 2-2A
B
Wire InsulationWire InsulationAC cables must be type UL 1426 BC
600 volt insulationGasoline and Oil resistantWon’t absorb moisture
DC wires & cables must be Marine Grade600 volt insulationGasoline and Oil resistantWon’t absorb moisture
Color coded wires MElec-Ch2 - 22
Wire Color CodeWire Color CodeColor AC (Hot) AC (Neut) AC (Gnd) DC + DC -Black X X1
White XGreen (may have a yellow stripe) XRed X2 XYellow X1
Footnotes: 1 – Yellow preferred for DC negative to avoid confusion with AC Hot wire 2 – 2nd hot wire in 220 VAC is Red
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Wire Color CodingWire Color Coding
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Wire TerminationsWire TerminationsCrimping
Special ToolApproved Marine ConnectorsUse of Ratcheting Tool
Solder
Heat-shrink TubingMElec-Ch2 - 25
Wire TerminalsWire Terminals
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Ratcheting CrimperRatcheting Crimper
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YES
NO
Ratcheting Tool UseRatcheting Tool UseFirst select appropriate connectorStrip 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 barrelCheck the connection with a solid tug
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SolderingSolderingTerminal connection can’t be only
solderedMust also be crimped
Soldering is normally not requiredCrimped connectors are acceptable to ABYCIf solder, apply only to ring end of terminal
Solder changes stranded wire into solidStranded wire is flexible
Use 40% lead / 60% tin, rosin core solderBattery lugs may be only soldered
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Heat-Shrink TubingHeat-Shrink Tubing
MElec-Ch2 - 30Application Steps
Coaxial CableCoaxial CableAntenna cableRadio coax is 50 ohm with PL-259Radio cable is cut to lengthWant attenuation under 3 dbTV cable is 75 ohm with “F”
connectorsGPS cable is not cut to length
Coil excess in 1-foot loops MElec-Ch2 - 31
Coaxial Cable InformationCoaxial Cable Information
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Soldering PL-259 Soldering PL-259 ConnectorConnector
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Wiring InstallationWiring InstallationBasic ConsiderationsDistribution PanelFuses / Circuit BreakersBranch Circuits
WireOutletsSwitches
Grounding SystemsBonding Systems MEl
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Basic ConsiderationsBasic ConsiderationsMust have source and return wires
Return wires to a common pointMay use feeder wire from power panel
for: engine, helm console, etc.
Wires above flood level of bilgeWaterproof if in bilge
Insulated support every 18”Twist DC wires within 1 meter of
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Distribution PanelDistribution PanelCentral location of Circuit Breakers / Fuses
All branch circuits from this location
AC and DC may be combined in one panelAll equipment / circuits should go to panel
Not direct to battery (except bilge pump) Noise interference suppression covered in Section 7
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DC / AC Power PanelDC / AC Power Panel
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Front View
Inside Power PanelInside Power Panel
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Buss Bars
Fuses and Circuit BreakersFuses and Circuit BreakersUsed to protect wiring from over
currentIn positive or hot wire
Newer boats use circuit breakersInitially more expensive
Replace blown fuse with correct ratingCircuit Breakers should be Marine
GradeTrip freeManual reset MEl
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Branch Circuits - WiresBranch Circuits - WiresMinimum size is 16 AWG
See Wire Selection TablesFor AC normally #14 for 15A and #12 for 20A
Must terminate in closed electrical box Of sufficient lengthDC negative returned to DC Panel
May use several negative feeder terminalsAC neutrals returned to AC PanelBonding system never used as return
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Branch Circuits - OutletsBranch Circuits - Outlets120 VAC outlets must be 3-wire polarized
Black (hot) to brass or copper colored terminal Outlet wires must have crimp terminalsGFI outlets
Required on weather deck, head, galley and machinery spaces
Good practice for all AC outlets to be GFITrip at 5 milliamps
Different outlets for AC and DC powerMElec-Ch2 - 41
Outlets and PlugsOutlets and Plugs
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DC Outlet(Receptacle)
DC Plug
120 VAC 120 VAC12 VDC 120 VAC
15 A Outlet
AC Plug 15 A
AC Plug 20 A
GFI 15 AOutlet
20 A Outlet
Branch Circuits - SwitchesBranch Circuits - SwitchesModern panels use Circuit Breakers
Which also double as switchesSwitches / Circuit Breakers
Must be Marine GradeRated for the voltage and current
controlledInterrupt the positive (DC) or hot (AC) leg
Battery SwitchDesigned for high current serviceNot located in engine or fuel-tank
compartmentsMElec-Ch2 - 43
Grounding SystemGrounding SystemGround is potential of water around boat
Or potential of earth’s surfaceDC – Ground Battery negative terminal(s)
Also engine blockWire color is Yellow (or Black)
AC – Transformer center tap on shoreAlso connected to ground rod at transformerWire 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
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Bonding SystemBonding SystemFor lightning protection
More in Chapter 6All metal objects should be bonded
Keeps all metal at zero potentialEngine blocksBattery negative terminals
Non-current carrying wireThrough-hull fittings
ABYC now recommends they be bondedElectrically isolated from metal hull MEl
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Bonding DiagramBonding Diagram
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Wiring DiagramsWiring DiagramsElements of a Good Wiring Diagram
Documents boat’s electrical layoutShould be kept currentUsed for troubleshooting
Component IdentificationPhysical objects to their symbolWires are color coded
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Wiring Diagram SymbolsWiring Diagram Symbols
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Switch, double pole, single throw (DPST)
Switch, single pole, single throw (SPST)
Switch, single pole, double throw (SPDT)
Battery (long line on top is positive)
Wires connected (at dots)
Wires crossing (but NOT connected)
Wire (insulated, metal conductor)Incandescent Light
Alternate symbol for Light
Circuit Breaker
Fuse
Ground
Male Connector
Female Connector
Simple DC Wiring DiagramSimple DC Wiring Diagram
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SummarySummaryCircuits should be off when working on themUse only marine grade properly sized wires
Tables will help determine proper wire size Minimum wire size is #16 AWG
Use wire terminations and ratcheting crimperDC circuits are 2 dedicated wires
Waterproof wire connection in bilgeAC circuits are 3 dedicated wires
GFCI in galley, head, machine spaces & weather deckSeparate Grounding & Bonding systems
requiredKeep wiring diagram current
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