Marine Electrical Check List
A Guide to Inspecting Marine Electrical Systems
This document is available on the Internet at
www.islandnet.com/robb/marine.html
and it is shareware.
copyright © Robb Zuk. All rights reserved.
Contents
Back to Contents
Introduction
This document is an explanatory guide for checking marine electrical
systems. There are some great,
detailed publications
on this subject and I recommend them for additional reading when
you have the time
For now, this check list will get you started with a minimum of
reading. I summarised points from Canadian, American and British
marine wiring regulations. However, I did not quote these publications
exhaustively so don't consider Marine Electrical Check List
a legal document.
Before working on your system, clarify
any confusing points with a professional electrician.
Researching and writing this document took several months of
my time -- I offer it on the Internet as shareware. If you
read it and use it, please send US$10 using this secure online payment button:
or mail your payment to:
Robb Zuk
2626 Lighthouse Lane
Pender Island, BC V0N 2M2
CANADA
Back to Contents
Stray Current (an explanation)
Stray current is electricity that is flowing where it's not supposed
to -- through water, fittings on your boat, wet wood, damp surfaces,
etc. It can be a shock hazard and it can cause corrosion (technically
known as electrolytic corrosion). Stray current corrosion
is caused by a power source such as your batteries or the shore
power connection. It is unlikely for serious corrosion to be caused
by stray currents flowing through the water, without a metallic
path to your boat. Because of the relatively high driving voltages,
stray current corrosion can act far more quickly than the corrosion
caused by dissimilar metals in contact (galvanic corrosion).
Note: The word electrolysis is often mistakenly used to
describe various kinds of corrosion. Electrolysis actually refers
to the bubbling off of gases that occurs with electrolytic corrosion.
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Common Ground Point (ship's ground)
- grounds from batteries, engine, switch-panel negative bus
bar, bonding system, auxiliary power generator, underwater ground
plate, ship's 120 Volt safety-ground,
and LORAN signal ground all meet at one point
This point must be a heavy bus bar or bracket with bolted connections.
Note: When referring to 12 Volt wiring, 'ground', 'negative'
and 'ground return' are all equivalent terms.
- easy to access and located as far above bilge levels as practicable
- labelled as Common Ground Point
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Batteries
WARNING! The hydrogen gas in and around lead-acid batteries is explosive and the acid can burn skin and eyes. Avoid sparks and wash
well after handling your battery.
- acid (electrolyte) level is up to plastic liner inside holes
Letting the acid level go below the top of the plates will
kill a battery quickly. Use distilled water to top up batteries.
If distilled water isn't available, tap water is OK if it's clear,
not 'hard,' and not highly chlorinated. Let the cold tap run for
a minute to clear metal ions out of the pipes and use a well rinsed,
glass or plastic container to transfer.
- fully charged specific gravity is 1.245 to 1.300 in each cell
- In a partially discharged battery, specific gravity of each
cell does not vary by more than 0.050 from the other cells
Battery cells sometimes charge with uneven specific gravities
but after discharging about 25% (from a full charge) they should
even out.
Note: If it's been awhile since charging the battery, acid may
have settled to the bottom leaving a lower specific gravity electrolyte
on the surface. If you overfilled the battery then the electrolyte
may be diluted. Either of these situations can result in abnormally
low readings and they don't necessarily indicate a weak battery
cell.
- 'at rest' battery voltage is 12.1 to 12.8 Volts
A battery is 'at rest' when it isn't being used and hasn't
received a charging current for at least 12 hours. A voltage above
12.8 Volts indicates that the battery is still settling after
a charge. A voltage below 12.1 Volts indicates either a weak cell
or a battery charge below 50% of capacity.
Note: Standard batteries have their life span shortened drastically
by deep discharges, even to the 50% level. True deep cycle batteries
(see below) function well with 50% discharges.
- engine cranks properly for 5 seconds with each battery alone -- battery
voltage is above 9.5 Volts and steady while cranking
Perform this test only after engine has been running so that
protective oil has circulated. Disconnect coil '+' wire or engage
diesel fuel shut-off mechanism to keep engine from starting. It's
possible for batteries to fail this high current test while still
being able to provide good storage capacity at lower currents.
Note: If engine doesn't crank properly and battery voltage remains
high, then there is a problem with the starting circuit or starter
motor.
Note: Starter or electric winch motors will normally 'pull' a
battery's voltage down to 9 or 10 Volts while they're operating.
The battery should recover most of its 'at rest' voltage within
seconds.
- batteries draw not more than a few amps of charging current
once they are charged
- except during conditioning (see below), water loss is at most
a few ounces (50 to 100 ml) per cell, per year
Significant water loss indicates a problem. If the water loss
occurs evenly in the cells, alternator or battery charger voltages
may be too high. Water loss in only one or two cells indicates
weak or shorted cells.
- batteries are true deep cycle type if used for anything but
starting
Specify that you want 'golf cart' batteries because most marine/RV
'deep cycle' batteries are only marginally better than automotive
batteries for deep cycling. True deep cycle batteries will provide
many hundreds of charge/discharge cycles instead of only a few
dozen.
Note: Avoid discharging deep cycle batteries below 50% of their
capacity. A 50% discharged battery has an 'at rest' voltage (see
above) of 12.1 to 12.2 Volts.
- top surfaces clean and dry
- cables in good condition -- ends are soldered and correct size
for terminal connectors
Check cables for broken or corroded strands, especially at
the ends.
- only one cable to each terminal
In particular, avoid small wires in battery compartment. Run
them to the battery switch and switch-panel negative bus bar instead.
- no connection depends on spring tension (i.e., no alligator
clips)
- connections cleaned and sealed
- positive terminals have insulating cover
- negative cables go directly to
Common Ground Point
Many systems have the negative cable running directly to the
engine as part of the starting circuit. This means that other
negative connections need to be at the engine, or in the battery
box, which can cause corrosion problems.
- positive cables go directly to nearby battery switch
- no batteries wired in parallel
Paralleled batteries tend to fight each other when they are
at rest -- this causes premature discharge and a shortened life
span. It's OK to parallel batteries temporarily with the battery
switch, while charging, starting and running the engine -- just
avoid leaving the switch on 'BOTH' when no power is being drawn.
If you require a large battery capacity, connect several 6 Volt
or even 2 Volt cells in series instead of wiring 12 Volt cells
in parallel.
Note: Two batteries are in parallel if their positive terminals
are connected and their negative terminals are connected.
- ventilation is provided for cooling and for venting the gases
produced by batteries
Batteries produce hydrogen, oxygen and corrosive sulphide gases.
The lighter-than-air hydrogen must be able to rise naturally through
a venting system, with or without a blower.
- batteries can be conditioned with an equalizing
current
After a normal full charge, conditioning consists of applying
a reduced charging current (2 to 5 amps for most batteries) either
for a few hours or until battery voltage rises to 15.5 - 16.5
Volts -- this takes the lead sulphate 'crust' off the battery plates
and helps maintain full storage capacity. Check the acid level
when finished because this process causes bubbling and fluid loss.
Condition batteries every month when they're being used heavily.
Conditioning requires either an override on the
alternator's
standard voltage regulator or a battery charger with a conditioning
or 'equalising' option.
Note: Don't condition batteries when they are in parallel or
one battery may take most of the conditioning current.
Note: Shut off all electronic equipment during conditioning
because of the high battery voltage.
- inlet vent below batteries
- outlet vent as high as possible in battery compartment
- if using an electric blower for battery venting, the motor
is not in the air stream
- ventilation system is for batteries only
- batteries strapped down and prevented from shifting
- battery compartment protected against acid spills
- easy to access and located as high above bilge as practicable
- if batteries are not being used, they are given a full charge
at least once every 3 months
Lead acid batteries will self-discharge over a period of months
so they should be charged periodically to ensure that they don't
completely discharge. This is especially important during freezing
weather because a discharged battery can freeze develop cracks
in the case.
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Connections
- all easily accessible and above bilge water levels
If you must make a connection in a poorly accessible spot,
solder it and seal it against moisture.
- soldered joints are first mechanically connected (crimped,
bolted or twisted) -- crimped or twisted connections are soldered
as well
Connections held by solder alone will fracture with little
stress. Some commercially crimped connections may be OK without
soldering but most are fallible in a marine environment. Make
sure solder is rosin core (60/40), not acid core.
- mechanical connections are strong (nut and bolt/stud, or machine
screw into tapped metal)
Self-tapping screws into fibreglass, wood, or thin sheet metal
don't provide the consistent high pressure required for a reliable
gas-tight (safe from humid air) mechanical connection.
Note: If you must use bare wire in a mechanical connection,
solder the end of the wire first. Wire strands that are 'mashed'
in a connector are very susceptible to vibration breakage.
- contact surfaces of mechanical connections are clean and coated
with moisture resisting sealant before being put together
Note: Sealant does not need to conduct electricity. When you
force two clean and sealed metal surfaces together with enough
pressure, high spots in the metals press against each other and
force the sealant aside. In this way, metal-to-metal contacts
occur all across a connection, with 'doughnuts' of sealant surrounding
each contact area. Use petroleum jelly (Vaseline), water resistant
grease, or a specialty product such as Lanacote for sealant. When
sealing light bulb bases, replaceable fuses and other friction
connections, 'rock' the connection back and forth a few times
to create good metal to metal contact while squeezing the sealant
aside. Applying sealant to the exterior of existing connections
will help prevent deterioration but may not last long. By sealing
the interior surfaces of a connection before you put it together,
you get a long lasting barrier to the moist marine environment.
- mechanical connections are locked
'Star' lock washers are best for bolted/screwed connections
because they dig into the metal surfaces, providing good metal
to metal contact.
- no connections made with wire nuts, wire screws or marrettes
If you insulate a soldered connection with a wire nut, turn
it up so that water can't collect in it.
- terminal connectors are ring type and correct size -- they are
not 'forked' or spade connectors
Ring type connectors hold best if a wire is accidentally pulled
or a connection becomes loose. Avoid spade or other 'push on,
pull off' connectors if possible. If you do use spade connectors,
they must be clean and sealed, provide solid mechanical contact,
be positioned so that water cannot collect in the connection,
and be anchored to protect against accidental pulling on the wires.
A better option is to install a terminal strip so that you can
make ring terminal connections. Seal these connections as well.
- terminal strips are easy to clean type (not enclosed), with
covers
- terminal strip uses minimum size #8 screws
Stripped threads are likely on smaller sizes.
- all connections that are at a voltage different from the
Common Ground Point
(i.e., all positive or 'hot' connections) are insulated with shrink
tubing or rubber boots
Electrical tape does not hold up well in a marine environment.
However, if tape is used for moisture sealing or to insulate an
awkwardly shaped connection, secure the finishing end with a wire
tie or cover as much of the tape as possible with shrink tubing
to keep it from unravelling.
- wires anchored next to connections for strain relief
In places where wire vibration or movement is unavoidable (e.g.,
some engine and bonding wires) make sure that only unsoldered,
uncrimped wire is moving. This may require heavy duty connectors
and shrink tubing on the wire next to connectors. In these situations,
leave a little extra wire in a loose coil so that movement of
any given section of wire is minimised and there is no chance
of the wire being pulled taught.
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Wires & Cables (conductors)
- 12 Volt system is all 'two wire' type
All devices have insulated, positive and negative wires running
to them. The hull or bonding system must not be used for the ground
because of potential corrosion problems.
- all wiring is stranded (no solid wire)
Solid wire is more susceptible to vibration breakage than stranded
wire. However, very finely stranded wire is likely to suffer corrosion
problems so it should also be avoided.
- routed as high above bilge water levels as practicable
- conductors not kinked or bent sharply
Sharp bends will fatigue metal which eventually can cause fracturing.
- insulation is flame retardant and moisture resistant -- in bilge
and engine compartment, it is oil resistant as well
- all wires have a flame retardant, moisture resistant (and
oil resistant, as above) protective sheath over their insulation
for the full length of the wire, except at the ends
- no frayed or cracked insulation
The engine compartment and bilge is a likely area to have faulty
insulation.
- wires are appropriate gauge for current being drawn and minimum
size is 16 gauge
Small wires break easily.
- 12 Volt system leaks less than 5 mA of current (test)
With all circuits off and the battery switch off, connect a
sensitive ammeter or LED indicator light across the battery switch
contacts to indicate current leakage. Bilge pumps and their float
switches are often a trouble spot so check this circuit as well
if it bypasses the battery switch.
- supported at intervals of not more than 45 cm (18") unless
running in bottom of conduit or trough -- supporting clips are screwed
down, not nailed
Wiring must not be able to move or flex with boat vibrations.
- if wiring is in conduit or troughs, drain holes exist to prevent
collection of water
- protected from mechanical damage in exposed areas
- protected from chafing where passing through bulkheads, junction
boxes, or other holes
- minimum of splices -- unavoidable splices are soldered and sealed
from moisture
- wires approach terminals and devices from below (use drip
loops if necessary)
Water that may run along wiring must not be able to wet connections
or devices.
- wire colour coding is not opposed to standards and is consistent
throughout the system
Some confusion exists with wire that is commercially available.
For example, 3-conductor AC wiring should have black for the hot
wire whereas most DC wiring uses black to indicate ground. To
make matters worse, 2-conductor wire often comes in black AND
white making it very similar to the 3-conductor AC wiring. AC
standards are: hot/black, neutral/white, and safety-ground/green
or bare. DC standards are: positive/red or colour coded as to
purpose, and negative/black or white. When 2-conductor wire uses
both black and white, white is positive and black is negative.
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Labelling & Diagrams
- every wire labelled at both ends
Label with descriptive words for ease of trouble shooting and
modification -- colour coding is often obscured by paint and numbering
requires the use of schematics. Tags can be made from white, marine-vinyl
and marked with an indelible, black felt-pen. I've found 'Sharpie'
extra fine points to be the best. Attach the labels with plastic
wire ties. If using tape on numbers, cover them with clear shrink
tubing since tape is unreliable in marine environments.
- every electrical system is documented in diagrams or schematics
and these indicate colour, relative size and labelling of wiring
- all diagrams, information sheets, operating manuals, etc.
in one location on board
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Battery Switch ('master' or 'main' battery switch)
- ignition protected (enclosed) and marine rated
- easily accessible for use and maintenance
- interrupts positive cables from batteries
- located near batteries
- switches off all systems except bilge pump circuit and possibly
entry alarm or electronic memories
- connections clean and sealed
- for each 'On' position, voltage drop is less than 0.5 Volts
in switch while engine is cranking
This is a test of resistance in the switch.
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Fuses, Breakers & Switches
- all circuits are fuse or breaker protected
The only exception to this may be the starter motor circuit.
- in 12 Volt system all fuses, breakers and switches in positive
side of circuits
Breaking the negative side of a circuit can cause
stray current
corrosion.
- breakers are trip free type (cannot be overridden)
- fuses or breakers rated not more than rating of the smallest
wiring they protect
- electric motor fuses or breakers rated not more than 125%
of maximum motor load
- no auto-resetting breakers (e.g., thermal cut-out breakers)
unless circuit is already protected by fuse or manually reset
breaker
- all fuses or breakers are located in switch-panel except,
perhaps, main fuse or breaker
If a fuse or breaker can't be in a switch-panel, it must be
in the battery end of the circuit. In-line fuses should be avoided
unless they're providing extra protection for a device on a shared
circuit. They must be very accessible and the protected end of
the fuse holder should connect to the positive wire coming from
the battery.
- in 12 Volt system, main positive conductor to switch-panel
is fuse or breaker protected as near to battery end of conductor
as practicable
- fuses have clean, tight,
sealed contacts
- switch-panel's wiring easily accessed for maintenance
- switch-panel ventilated
- switch-panel compartment and junction boxes not flammable
and not metal
- all switches labelled
- if engine is gas powered, switches in engine and fuel tank
compartments are ignition protected and approved
- switches in head, cockpit and other moist areas have rubber
covers for moisture protection
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Bilge Pump System
- wiring runs above bilge water levels where possible
- float switch is protected from being jammed open by debris
- there is a high-volume, manually-operated emergency pump
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Alternator
- with engine running, batteries fully charged and a 1 or 2
Amp load on system (a light turned on), voltage to batteries is
13.9 to 14.4 Volts -- voltage remains constant as more loads are
turned on, up to the rated output of the alternator
With constant voltage regulators (most common), a high voltage
setting will slowly fry the batteries unless the engine is used
very little. A low voltage setting causes slow charging.
Note: Most voltage regulators can be overridden with additional
circuitry to provide fast charging while at anchor, or to condition
batteries. The override circuitry can
be as simple as a switched resistor or automatic as with Spa Creek's
M.A.C. (Manual Alternator Control) or Cruising Equipment Co.'s
QuadCycle regulator.
- IF it has ground terminal, a heavy wire connects it
to the Common Ground Point or
engine block
ELSE: connection between alternator housing and engine
block clean and sealed
When an alternator doesn't have a separate ground terminal,
the negative connection is made between the alternator housing
and the engine block. This connection must then be treated the
same as any other electrical connection.
- alternator field cut-off switch on battery switch
OR: 'Zap stop' voltage transient suppresser on output
(available from Cruising Equipment Co., Seattle)
OR: battery isolator/charging diodes in alternator output
Any of these devices will protect the alternator if the battery
switch is accidentally shut off while the engine is running.
- power to the voltage regulator supplied through an oil pressure
switch unless supplied internally from alternator
Some regulators are powered directly from the ignition switch.
This means the engine is loaded down by the alternator even before
protective oil has circulated. It's better for the engine to have
the alternator turn on after oil pressure has built up.
- voltage regulator is external to alternator
Some voltage regulators are located inside the alternator housing.
This makes repair or replacement a time consuming job.
- brushes and slip rings clean and in good condition
- bearings in good condition
- external connections clean and
sealed
- drive belt(s) tight and in good shape
Note: Good quality, toothed V-belts last longer and are more
efficient than solid V-belts because less heat builds up in the
belt.
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Starter
- IF starter motor has ground terminal, a heavy cable
connects it to the Common Ground Point
or engine block
ELSE: connection between starter frame and engine block
clean and sealed
Since starting currents are so high, good connections are crucial.
Run the engine ground cable directly to the starter's mounting
bolts or to the starter's ground terminal if it has one.
- brushes and commutator clean and not too worn
- bearings/bushings in good condition
- solenoid plunger clean and lubricated
- solenoid internal contacts clean and not pitted
High current arcing between the solenoid's main contact surfaces
makes them subject to pitting and therefore poor electrical contact.
- external connections clean and
sealed
- starter motor gets 9.0 Volts or more while cranking engine
This is a test of batteries, cables, connections and solenoid.
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Anchor Winch / Windlass
- fuse or 'trip free' (cannot be overridden) breaker located
in positive cable near batteries
- main current switching done through a solenoid
Remote mounted starter solenoids, such as those used in older
model Fords, are suitable. Many momentary switches are not rated
for the high current drawn by winch motors or the arcing caused
by such a large inductive load. Pitting in the contact surfaces
can cause the switch to 'stick' and leave you with a runaway winch
- brushes and commutator clean and not too worn
- bearings/bushings in good condition
- connections sealed and protected
from anchor chain or line
- electric motor gets 9.0 Volts or more when running under load
This is a test of batteries, cables, connections and switches/solenoids.
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Battery Isolator (charging diodes)
- alternator output voltage is raised to compensate for the
voltage drop in charging diodes unless the diodes are connected
across battery switch
Charging diodes lower the voltage received by the batteries.
If this is not accounted for, charging will occur too slowly.
Note: If the diodes connect ACROSS battery switch, DON'T
adjust the alternator output. In this case, the switch bypasses
the diodes when it is 'on' -- no diode voltage drop occurs and
the batteries charge normally.
- good ventilation for cooling
Charging diodes can generate a lot of heat
Note: Battery isolators or charging diodes only isolate batteries
from each other in the alternator or charger circuit. The batteries
are NOT isolated when the battery switch is on 'ALL.' To
avoid the problem of paralleled batteries discharging and harming
each other, the battery switch should be on 'ALL' only while starting
or running the engine.
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Battery Charger
- 120 Volt side electrically isolated from 12 Volt side (test
at 120 VAC if qualified)
- ammeter to indicate output
- overload protection on output
- charger shuts off completely or drops to 13.0 - 13.2 Volts
(float voltage) after charging batteries
Float voltages of 13.8 Volts or more are common and these will
eventually fry your batteries. If the charger doesn't have a proper
float voltage, leave it off except when you need it. It's far
better to leave batteries alone, and give them a charge every
few months, than to have them at a high float voltage. If you
must leave a charger turned on, (e.g., with fridges or heavily
used bilge pumps), make sure it has a proper float voltage.
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120 Volt AC System
WARNING! 120 Volt systems can be dangerous, especially
in marine environments. Don't use your system if you have any
doubts about its safety. Don't work on your system if you are unsure
of what you're doing.
Following are two key points to a safe 120 Volt system:
- The hot (black), neutral (white) and safety-ground (green
or bare) wires must be intact and not mixed up (see AC System
Warning Device, below).
- All current must flow in the hot and neutral wires
only. Current flowing anywhere else is 'stray', a fault condition
and presents a shock and corrosion hazard. GFCIs (Ground Fault
Circuit Interrupters) ensure or an isolation transformer that current
flows only in the hot and neutral wires. GFCIs trip if they detect
a loss of current from the hot or neutral wire. Isolation transformers
allow current to flow only in the hot and neutral wires.
Note: No safety system protects against shock if you touch
both hot and neutral wires at the same time. By touching both
wires, you are no different from a light bulb or toaster since
you are actually in the hot and neutral circuit. This can be fatal!
Luckily, most fault conditions occur when current is able to flow
outside of the hot and neutral circuit. This is the situation
that GFCIs and isolation transformers protect against.
- ship to shore plug connector has a locking cover and is insulated
from the hull with a rubber gasket
- ganged, double-pole main breaker is the first part of ship's
system and it is easily accessible
The main breaker must disconnect both hot (black) and neutral
(white) wires simultaneously.
- main breaker rating is appropriate for ship to shore plug
connector and wiring used
- all power indicating devices are wired to hot (black) and
neutral (white) wires only unless switched by a 'momentary on'
switch
For example, reverse polarity (hot and neutral reversed) detectors
are wired between neutral and safety ground or ship's ground.
If the detector is permanently wired into the circuit, it can
cause stray current corrosion by allowing
current to flow in the safety-grounds or through the bonding system.
Note: A momentary switch is not required if the device uses
circuitry to keep it from drawing more than 1 mA in safety-grounds,
ship's ground, or bonding system.
- AC system warning device is testable and indicates reverse
polarity, open safety-ground, hot on ground, etc. (all are dangerous
conditions)
Note: Unless your AC safety indicating system is quite sophisticated,
it is a good idea to have a plug-in AC outlet tester. They cost
$10 to $15 and test most dangerous conditions with their 3 lights.
Do not leave this tester plugged in because it causes current
to flow in the safety-ground, which is a cause of stray current
corrosion.
- no connection from either hot (black) or neutral (white) wires
to any part of 12 Volt system, including bonding system (test
at 120 VAC if qualified)
A connection between 120 Volt AC hot or neutral wires and the
12 Volt system would be potentially dangerous and could cause
stray current corrosion. This problem can occur with AC appliances,
such as battery chargers or hot water heaters, and with poor insulation,
wet connections, or broken wires.
- wiring is stranded 3-conductor and is 14 gauge minimum
- ends of bare wires are soldered before screw connecting
Bare stranded wire will break easily if it is 'mashed' under
a screw head.
- all connections (especially 'hot' ones) in switch-panel or
other accessible areas are insulated
Many commercially available panels contain both AC and DC systems,
with all terminals exposed. The 120 Volt terminals must be insulated
for safety.
- all connections are accessible only with the use of tools
We wouldn't want tiny exploring hands endangering themselves
would we?
- all switches, fuses and breakers disrupt the hot (black) wire
Breakers may be the ganged, double-pole type, which disrupts
both hot and neutral (white) wires simultaneously. The neutral
wire must not be broken while the hot wire is intact.
- no fuses, breakers, or switches in safety-ground (green or
bare)
- outlets in head and galley are protected by a GFCI (Ground Fault
Circuit Interrupter)
Most regulatory bodies require GFCI protection in heads and
galleys since they tend to be especially wet spaces. However,
since boats can be wet all over I highly recommended that GFCIs or an
isolation transformer be installed to protect the entire 120 Volt system.
- all 120 Volt outlets are 3 prong, grounding type and are incompatible
with 12 Volt DC outlets
- outlet faces clean and terminals coated with a moisture resistant
sealant such as petroleum jelly
120 Volt AC current leakage is likely with dirty or moist outlets.
This leakage can cause GFCI devices to trip and, in extreme cases,
can cause stray current corrosion or be a shock hazard.
- if there's an on board 120 Volt AC power source (generator
or inverter) wired into the system, there is a DPDT (double-pole,
double-throw) switch in the hot (black) and neutral (white) wires
that switches the system between shore power and ship's AC power
source
Shore power and the ship's AC power source must not connect
to each other or sparks can fly!
- all wiring enters its destination from below (or in a way
that won't allow water drips to enter)
- AC system is one of the following three types:
- Fully GFCI protected:
- all circuits protected by GFCI (Ground Fault Circuit Interrupter) devices
GFCIs are available as both circuit breakers and outlets. GFCI
outlets must be in a circuit already protected by a circuit breaker
(usually 20 Amp maximum)they do not function as an overload protector.
GFCI outlets can be wired to protect the rest of the circuit, continuing
from that outlet. GFCI devices must have a test feature and they
should be tested monthly to ensure safety and corrosion protection.
Note: The entire AC system could be protected by a single
GFCI main breaker. However, this is not advisable if you have many
AC circuits because the combined leakage of all AC devices could
trip the GFCI unnecessarily. For large systems each circuit should
have its own GFCI device.
- shore safety-ground (green or bare) continues as far as first
GFCI device, stops there and does not connect to anything at that
point
- ship's safety-ground (green or bare) starts at the first GFCI
device, connects to GFCI and its box and continues from there
- ship's safety-ground is connected to
Common Ground Point
- no connection from shore safety-ground to Common Ground Point
(test at 120 VAC if qualified)
The connection from shore safety-ground to ship's ground can
allow stray current corrosion. This connection is safely avoided
only with complete GFCI protection or an isolation transformer
system.
- Isolation transformer protected:
- all AC current supplied through an isolation transformer located
between main breaker and switch-panel
The transformer should be marine rated and large enough to
supply all circuits used on board.
- if neither secondary wires (ship side of transformer) are
grounded to Common Ground Point, all circuit breakers are ganged,
double-pole type
- shore safety-ground (green or bare) connected to isolation
transformer case only
- ship's safety-ground (green or bare) connected to Common Ground
Point
- no connection from shore safety-ground to Common Ground Point
(test at 120 VAC if qualified)
The connection from shore safety-ground to ship's ground can
allow stray current corrosion. This connection is safely avoided
only with complete GFCI protection or an isolation transformer
system.
Note: GFCIs are not required with a correctly operating isolation
transformer but may be added as protection against a malfunctioning
transformer.
- Incomplete GFCIs, no isolation:
- missing or incomplete GFCI (Ground Fault Interrupter) protection
and no isolation transformer
- AC safety-grounds (green or bare) from shore and ship are
connected together and to
Common Ground Point
In this system, the connection between ship and shore
safety grounds, and ship's ground is critical for protection against
shock hazard and stray current corrosion. This connection does
not protect against someone touching the hot (black) wire directly
while in contact with bilge, sea, or bonding system. A GFCI or
isolation transformer system would protect in this case.
Note: Connecting the ship's safety-ground to ship's ground
only, or to shore safety-ground only, can create a shock and corrosion
hazard in this system.
Note: Without complete GFCI or isolation transformer protection,
the safety-ground system must be solid on boat and shore to get
the protection it can provide. While this 120 Volt AC system
is common, it provides limited safety protection and allows several
kinds of stray current corrosion to occur since your boat's underwater
metal parts are electrically connected to other boats and to the
shore system ground. DC stray current can be blocked with a 'galvanic
isolator' (diode or capacitor type) connected in series with the
safety-ground wire. However, high voltage AC stray current cannot
be blocked safely. For these reasons, the full GFCI or isolation
transformer systems (#1 and #2 above), which safely eliminate
the shore safety-ground to ship's ground connection, are highly
recommended.
Back to Contents
Meters
- DC voltmeter can be read to nearest 0.1 Volt
A voltmeter allows monitoring of alternator and charger operation.
A sensitive voltmeter will also indicate storage capacity remaining
in batteries.
- DC ammeter showing alternator output
An ammeter is usually part of engine instrumentation. It allows
monitoring of alternator operation.
- DC ammeter indicating power drawn from batteries
An ammeter for the switch-panel can indicate faults in individual
circuits. The meter's resolution should be better than 1 Amp (.01
Amp or 1 mA resolution is best). An indicator light for small
current leaks is desirable and simple to install.
Note: The connections on DC ammeters (or their shunts) carry
full current so they must be clean, sealed
and locked.
- AC voltmeter and ammeter in system if shore power used extensively
or if there's an on board AC generator (alternator)
AC meters show the status of shore power or generating system
and can indicate faults in the ship's AC system.
Note: A meter can be installed to monitor the functioning of
your zinc, anti-corrosion system.
Back to Contents
Bonding and Lightning Protection
Four reasons for a bonding system are:
- Electrically connect metal fittings for corrosion protection systems.
- Protect metal fittings from stray currents originating on board.
- Reduce electronic interference (noise) for LORAN and radios.
- Provide a safe path for lightning strikes and the high voltages
induced in metal objects by a lightning strike.
- system uses heavy conductors -- minimum size is 8 gauge wire
or 1 mm x 10 mm (1/32" x 1/2") copper or bronze bar
Some sources recommend a heavier conductor (up to 2/0 gauge)
for the main lightning path which is down the mast, along the
main bonding conductor, and out to the shaft and prop and/or underwater
grounding plate.
- all connections above normal bilge water levels
- all connections accessible, clean, bolted and soldered
or sealed
Soldered connections must first be well connected mechanically
since solder is weak. Also, solder can melt with the high current
of a lightening strike.
- conductors are run with no sharp kinks or bends
Sharp bends will fatigue metal and can eventually cause fracturing.
- conductors run separate from other wiring as much as practicable
The high current of a lightning strike can cause equipment
damaging voltages to be induced in nearby wiring.
- insulation (optional) is green or yellow
Note: This system is separate from the 120 Volt safety-grounds
which may also be green.
- does not normally carry current (except for corrosion protection
current)
Do not use the bonding system in place of negative power wires
(i.e., as a 'ground return') or stray current corrosion problems
can result.
- the 'main bonding conductor' runs near the centre line of
the ship and connects to the
Common Ground Point --
all other bonding conductors connect to the main bonding conductor
or directly to the Common Ground Point
Running bonding conductors from one fitting to another increases
the risk of shock and corrosion damage if stray currents run through
the bonding system. Each bonded fitting should have only one connection
point and one wire running to it.
- bonding system connects with DC power system at Common Ground
Point only (test)
- The following connections exist to reduce the danger from
stray currents originating on board:
Note: These connections also provide the basis for hull-mounted-zinc
or impressed-current corrosion protection systems and are part
of the lightning protection system.
- rudder shaft (if not mild steel) to main bonding conductor
- trim tabs to main bonding conductor
- propeller and shaft to main bonding conductor via wiper on shaft
The prop shaft wiper provides a path for corrosion protection
current. It also allows lightning strikes to ground through the
propeller (at least one square foot of underwater metal is required).
Make sure that wiper is on the propeller side of any non-conducting,
flexible shaft couplers or install a jumper wire over the shaft
coupler.
Note: Electrical contact through lubricated gears and bearings
is unreliable. Therefore, the engine block connection must not
be counted on to connect the propeller and shaft to the bonding
system.
- shaft support strut/bracket (if not mild steel) to main bonding
conductor
- metal through-hull fittings to main bonding conductor
Thru-hull fittings that are electrically isolated, in little
danger of stray current corrosion
and remote from protective zincs, need not be bonded (fittings
that are far away from your zincs are not protected anyway). Keeping
these fittings unbonded is desirable since a large system is more
likely to pick up stray currents flowing through the water.
- if equipped with underwater ground plate, it is connected
to Common Ground Point
- engine block to Common Ground Point
The engine block is often connected to the Common Ground Point
as part of the starting circuit.
- other metal components, that are exposed to water and require
protection from corrosion or stray currents, are connected to
the main bonding conductor.
Note: Underwater metals that are widely separated in the Galvanic
series (e.g., mild steel and stainless steel) must not be electrically
connected. For example, a mild steel rudder should have its own
attached zinc and must not be connected to a bonding system containing
bronzes or stainless steel. Otherwise, the brasses and stainless
steels will be over-protected, causing wasted battery power or
a shortened zinc life span and possible alkali rot in wood hulls.
Also, if the corrosion protection system were to fail, the mild
steel would be attacked by the more noble brasses and stainless
steels. With zinc or impressed-current protection, bronze, stainless
steel, monel, lead and some other alloys are compatible.
- The following connections exist for lightning protection:
- each piece of metal standing rigging (stays and shrouds) to
main bonding conductor
- if mast is metal, mast base to main bonding conductor
- if mast is not metal, a copper spike extends 15 cm (6")
above top of mast and a conductor runs from the spike down mast
to main bonding conductor
If lightning does not have a metallic path to the sea, it can
travel through wood or you causing serious damage.
- if equipped with masthead antenna, it is a metal whip on a
base loading coil and it is well connected to mast or mast conductor
Various kinds of lightning arresters are available to provide
protection for antenna cables and radios.
- all metal parts of fuel system (tanks, lines, electric pumps,
valves and fill fittings) to main bonding conductor
- metal water and holding tanks and their fill hardware on deck
to main bonding conductor
- large or long metallic items (steering and engine control
cables, sail tracks, stanchions and life lines, pulpit, cockpit
railing, stove, chimneys, sinks, metal cabinets, etc.) to main
bonding conductor
Back to Contents
Corrosion Protection
- if hull is wood, all fasteners are same type of metal
In wet wood, different metals that are near to each other can
cause galvanic corrosion to the less noble metal (zinc is one
of the least noble metals). For example, galvanised fasteners
would have a shortened life if bronze fasteners were nearby.
- galvanized fasteners used underwater are hot-dipped type
Zinc plated fasteners will rust quite quickly because the protective
plating is not very thick compared to a hot-dipped zinc coating.
- fasteners or fittings that are exposed to water are not made
of brass, naval bronze, or manganese bronze
These metals have a high zinc content and will corrode severely
due to 'dezincification.' Most true bronzes (silicon, aluminum,
or phosphor bronze) are OK under water, provided they aren't in
contact with incompatible metals.
Note: Do not use household-plumbing type gate valves in salt
water systems because they are usually made of brass.
Note: Propellers and shafts are sometimes made of brass or
manganese bronze. Dezincification of these fittings can be slowed
down with zinc or impressed-current protection systems.
- fasteners are same metal as fittings, or slightly more noble
than fitting
Note: Through-hulls are a particular problem area for underwater
corrosion. Through-hulls and their fasteners should both be made
of a true bronze.
- no copper in areas of fast moving water (e.g., exhaust elbows)
Copper corrodes very little in still water but suffers from
impingement attack (a type of corrosion) in fast moving water.
- no copper alloys (brass, bronze, etc.) within 60 cm (2') of
aluminum outdrive
Underwater aluminum can corrode severely in the vicinity of
copper so existing copper alloy parts should be painted with epoxy
paint to help minimise their impact.
- no electrical path from underwater aluminum to any other underwater
metals (test)
Underwater aluminum will galvanically corrode when electrically
connected to most other underwater metals. Magnesium and zinc
are exceptions that can be used to protect aluminum.
- aluminum masts, outdrives or other fittings exposed to the weather
use stainless steel fasteners and are in contact with no metals other
than aluminum, stainless steel, galvanised steel, or monel
Copper and copper alloys such as brass and bronze must not
be joined to aluminum that is exposed to the weather because of
the vigorous galvanic corrosion
that they can cause. Stainless steel is much more noble (further
from zinc) than aluminum but it develops a protective oxide coating
so corrosion of the aluminum is minimal. Also, the corrosive effects
of a small stainless fastener are spread out over a relatively
large area of the aluminum fitting and so it will do little concentrated
damage.
- hot-dipped zinc or galvanised metals (chains, anchors, etc.)
in contact with galvanised, hot-dipped, or mild steel metals only
Severe corrosion can result from mixing these metals incorrectly.
Do not use galvanised chain on a stainless steel anchor, stainless
shackles on galvanised chain, or stainless wire on a galvanised
shackle, etc.
- stainless steel used with caution underwater
Stainless is great underwater except when oxygen is not available
to its surface, as happens under marine growth, in wet wood, inside
stuffing blocks and rubber bearings, and underneath fittings.
When stainless is in these common situations, deep pitting (crevice
corrosion) of the metal can occur and structural failure can result.
If stainless components are used underwater, they must be well
bedded in waterproof 'goop' to exclude moisture from underneath
the fitting and they should be inspected annually to check for
pitting. Stainless fasteners in damp wood are particularly prone
to crevice corrosion and should definitely be avoided. If stainless
fasteners or bolts are used underwater, lots of goop must be placed
on their threads, in the pre-drilled hole and under and around
the head of the fastener to seal out moisture. These fasteners
or bolts must be withdrawn periodically to inspect for crevice
corrosion.
Note: Stainless steel that is connected to a zinc or impressed-current
protection system will not necessarily be protected. Crevice corrosion
occurs where oxygen cannot get to the metal's surface. If oxygen
can't get to the surface then it's very likely that protective
current won't be able to either.
Note: Use only 'austenitic' stainless steels in marine applications.
These steels can be differentiated from other steels with a magnet,
which will attract them very weakly or not at all. The stainless
should preferably be type 316 or better. Type 304, or 18/8, stainless
is the most common but is not as corrosion resistant as 316.
- if propeller, prop shaft, or rudder shaft are stainless steel,
waterproof grease or thread sealant is used to keep salt water
out of threads, shaft taper and key way
Note: Make sure grease is not graphite based.
- underwater stainless fittings are fastened with monel fasteners
- no gaskets containing asbestos or graphite and no underwater
use of graphite based grease or graphite impregnated packing
Asbestos and graphite are very noble in the galvanic series
(opposite of zinc) and will, therefore, corrode most metals they
are in contact with.
- no copper, mercury, or lead based anti-fouling paint on aluminum
or mild steel
In general, no metal based anti-fouling paint should be used
on metal unless you know that they are compatible or an appropriate
type of sealer coat is first applied to the bare metal.
- keel bolts in good condition and compatible with keel material
- centreboard pivot and lifting gear in good condition and made
of compatible materials
- fittings that are in the bonding system are painted and isolated
from wood as much as practicable
Painting a fitting will reduce the amount of protective current
it requires. Isolating it from the wood with paint or gaskets
will protect the wood from hydroxides created by the protective
current. These precautions minimise the damage by alkali rot to
wood around protected fittings.
- if engine or its cooling system uses internal zinc protection,
zincs are not corroded away
Zinc corrosion protection system:
A protective current flows through metals that are electrically
connected to the zinc. The current is forced by the galvanic voltage
difference between zinc and the underwater metal parts of the
boat. Metals that are too far away from the zinc will receive
little protective current.
- zincs are bright, unpainted and not corroded away
Note: There may be zincs in the engine block, in heat exchangers,
on the rudder, or on outdrives.
- zinc connection locked with star washer and moisture sealed
Zincs that are cast around a mounting bar are best. If you
have stud mounted zincs, use a waterproof goop to seal in and
around the mounting hole. This will help prevent corrosion that
can lead to loosening of the zinc by undermining the stud connection.
- shaft zincs not too near propeller
A zinc on the shaft can cause turbulence which will decrease
the efficiency of the propeller. Shaft zincs also tend to protect
only the forward part of the propeller. It's better to have hull-mounted-zincs
connected to the shaft via a shaft wiper
(see Bonding System).
- appropriate protection current is flowing (10 to 25 mA, or
more, per square foot of bare metal to be protected, depending
on many factors)
Note: Too much protective current can seriously damage wood
or, in extreme cases, aluminum around protected fittings. Too
little current will not provide adequate protection of fittings.
With a wood hull, it's cheaper to err on the side of too little
protective current since most underwater fittings are reasonably
corrosion resistant anyway.
- there is a meter for monitoring protection current
A protection current meter is easy to install with a hull-mounted-zinc
system. It will show how much protection is being given and when
zincs need replacing. It will also indicate problems in the system,
including stray currents. The meter should be 1 Amp (1000 mA)
full scale and have a remote shunt. The shunt should have a pair
of 40 Amp Schottky diodes wired in parallel with it, one in each
direction, to protect the meter from lightning or electrical fault
current surges. The remote shunt is important for allowing lightning
strikes to flow directly to the sea, without first being routed
up to your meter location.
Note: Stray currents picked up by a bonding system will corrode
any attached zincs before damaging other metals.
Current limiting systems:
These systems are essentially the same as a hull-mounted-zinc
system except that current limiting circuitry is placed in the
wire running to the sacrificial zinc, allowing an extra large
zinc to be used. Current is held at an appropriate level and the
zinc may last for several years or more. These systems may have
reference anodes mounted on the hull as well as the sacrificial
zincs.
- follow manufacturer's instructions for maintenance and make
sure it's working
Impressed-current systems:
Impressed-current systems 'force' a protective current to flow,
using battery voltage instead of the natural voltage present between
zinc and the bonding system. An underwater anode is still required
but it is made of some non-corroding metal instead of zinc. Reference
anodes may also be required with this system.
- follow manufacturer's instructions for maintenance and make
sure it's working
Back to Contents
Compass (traditional, fluxgate and autopilot compasses)
- not affected by operation of any of ship's equipment -- check
on two perpendicular headings (e.g., N and W)
Any DC current flow and most electronic devices can affect
the compass if they're nearby. Check everything.
Note: AC current does not affect compasses so the next
three points do not apply to 120 Volt wiring.
- no wires carrying heavy current nearby
- no single wires near compass
The switch-panel's main ground wire and the alternator output
wire are examples of potential problems because they carry a lot
of current and they often run alone. When both positive and negative
wires of a circuit run together, their opposite magnetic fields
tend to cancel each other out.
- if wiring is nearby, it has both conductors tightly twisted
together
- no speakers, swinging needle meters, transformers, ignition
coils, or other magnetic devices nearby
Speakers often contain powerful permanent magnets. They should
be at least 1.5 m (5') away from any compass.
- no metal objects nearby unless they're non-magnetic
Steel and iron usually cause most of the problems. Stainless
steel and aluminum should be OK. All nearby metals should have
their effect on the compass checked.
- autopilot and steering compasses separated by 1 m (3') or
more (check their effect on each other)
Back to Contents
Electrical Interference (noise)
- GPS, LORAN, autopilot, VHF, RADAR, depth sounder, etc. continue
to operate properly when other electrical systems are turned on --
Do not perform this test with engine starting circuit
or winch motor!
No electronic device should be 'on' while the engine is being
started or the winch is operating unless they are in an isolated
circuit. The voltage transients or 'spikes' generated by starter
and winch motors can cause damage to sensitive electronics. In
this test, watch for noise generated by gas engine ignition systems,
alternator, DC to AC inverters, depth sounder, RADAR, strobe light,
fluorescent lighting, electric motors, electric fuel pumps, VHF
and SSB radios. Note that electronic noise can be transmitted
through wires or air. For example, a LORAN may have poor reception
due to noise in its power cable or noise picked up by its antenna.
- autopilot, RADAR, inverter and SSB radio have their own circuits,
with the wires running separately from wires for sensitive electronics
- able to isolate autopilot circuit
Some electric autopilot motors can cause noise problems for
electronics (e.g., LORAN). If this happens, isolation is desirable.
This can be achieved by directly wiring the autopilot circuit
to one battery (at battery switch) and running the system on the
other battery. Alternatively, the LORAN can have an isolated power
supply by having its own small battery, which is wired to the
system with appropriate filters for charging.
- LORAN has at least 8 gauge conductor for 'signal ground' connection
to Common Ground Point
- power wires for sensitive devices run separately from other
wiring, especially alternator output, engine instrument and electric
motor wires
Wires that run parallel and close to each other can cause problems.
However, wires may cross without affecting each other. Shielding
may be required if close parallel wiring can't be avoided.
If noise problems continue after following the above suggestions,
filtering of offending and/or sensitive circuits may be necessary
Back to Contents
Miscellaneous
- depth sounder transducer is free of marine growth and has
thin or no paint layer on bottom surface
- if propane or gasoline are used on board, appropriate sensing
devices are installed to warn of leaks
- autopilot, VHF, RADAR, SSB and other critical, high-power
devices have an input voltage that differs from battery voltage
by less than 0.5 Volts while operating
The voltage drop in a circuit is an indication of the condition
of connectors, switches and wiring.
- solar panels have diodes in their circuits
Without diodes, solar panels can take power from the batteries at night.
Back to Contents
Pre-Cruise Mini Check List
Maintenance check points are covered only briefly here. For explanations
and construction check points, see the
main sections of the check list
Batteries
- top surfaces clean and dry
- acid (electrolyte) level up to plastic liner inside holes
- fully charged specific gravity is 1.245 to 1.300 in each cell
- In a partially discharged battery, specific gravity of each
cell does not vary by more than 0.050 from the other cells
- 'at rest' battery voltage is 12.1 to 12.8 Volts
- engine cranks properly for 5 seconds with each battery alone -- battery
voltage is above 9.5 Volts and steady, while cranking
- cables are in good condition
- connections clean and sealed from moisture
Back to Contents
Wiring & Connections
- contact surfaces of mechanical connections are cleaned and
coated with moisture resisting sealant before being put together
- no frayed or cracked insulation (check bilge and engine compartment)
- 12 Volt system leaks less than 5 mA of current (test)
- battery switch connections clean and sealed
- for each 'on' position, voltage drop is less than 0.5 Volts
in battery switch, while engine is cranking
- fuses have clean, tight, sealed contacts
- every electrical system is documented in diagrams or schematics
and these are in one location on board
Back to Contents
Alternator, Starter & Winch Motor
- with engine running, batteries fully charged, and a 1 or 2
Amp load on system (a light turned on), voltage to batteries is
13.9 to 14.4 Volts -- voltage remains constant as more loads are
turned on, up to the rated output of the alternator
- brushes and slip rings or commutators are clean and in good condition
- bearings or bushings in good condition
- external connections clean, sealed from moisture, and positive
terminals are covered
- alternator drive belt(s) tight and in good shape
- starter solenoid plunger clean and lubricated
- solenoid internal contacts clean and not pitted
- starter and winch motors get 9.0 Volts or more while operating
Back to Contents
Miscellaneous
- 120 Volt AC outlet faces clean and terminals coated with a
moisture resistant sealant such as petroleum jelly
- underwater stainless steel fittings and fasteners not pitted
- if engine or its cooling system uses internal zinc protection,
zincs are not corroded away
- corrosion protection zincs bright, unpainted and not corroded away
- in corrosion protection system, appropriate protection current
is flowing (10 to 25 mA, or more, per square foot of bare metal
to be protected, depending on many factors)
- compasses not affected by operation of any of ship's equipment -- check
on two perpendicular headings (e.g., N and W)
- LORAN, autopilot, VHF, RADAR, etc. continue to operate properly
when other electrical systems are turned on --
Do not perform this test with engine starting circuit
or winch motor!
- depth sounder transducer is free of marine growth and has
thin or no paint layer on bottom surface
- if propane or gasoline are used on board, appropriate sensing
devices are installed to warn of leaks
- autopilot, VHF, RADAR, SSB and other critical, high-power
devices have input voltage different from battery voltage by less
than 0.5 Volts while operating
Back to Contents
Electrical System Spares
- fuses (check electronic devices for internal fuses)
- bulbs
- VHF antenna that will connect directly to radio
- alternator belt
- alternator brushes (most alternators have brushes)
- voltage regulator for alternator and/or a method of 'hot wiring'
alternator field coils for emergency charging
- 4 litres (1 gallon) of distilled water
- engine starter solenoid
- winch motor solenoid
- if gas engine, complete set of ignition system parts
- plug-in AC outlet tester (has 3 indicator lights, costs $10 to $15)
Back to Contents
References
- The Bullet Proof Electrical System, Cruising
Equipment Co., Seattle, 1986.
- Construction Standards for Small Vessels, Canadian
Coast Guard, Ship Safety Branch, Part V, 1978.
- Corrosion Related Problems, Ed McClave, WoodenBoat
magazine #93 (April, 1990), pp. 94-113.
- Electrolysis and Corrosion (3 parts), Jerry Kirschenbaum,
WoodenBoat magazine #23, #24 & #25 (July - November, 1978).
- Metal Corrosion in Boats, Nigel Warren, 1980.
- Rules and Regulations for the Construction
of Wood
and Composite Boats, Lloyd's Register of Shipping, 1966,
pp. 171-184.
- Standards and Recommended Practices for Small Craft,
American Boat and Yacht Council, Inc., 1990-91.
- The 12 Volt Doctor's Practical Handbook, Edgar
J. Beyn, 1983.
- Your Boat's Electrical System, Conrad Miller
and E.S. Maloney, 1988.
Comments welcome!
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Marine Electrical Check List, copyright © Robb Zuk
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