- Action: To Do List item A0178 - Obtain replacement 12 VDC circuit breakers.
- Completed: 22 October 2017
- Cost: $106.83
New circuit breakers were needed to replace broken circuit breaker switches discovered during initial inspection.
Researched the internet and located a installation manual for the BEP Marine Model 905DV DC Circuit Breaker panel that was installed aboard. The manual specified that Airpax IEG and IUL magnetic circuit breakers are used in BEP Marine DC Circuit Breaker panels. Located a Airpax manual that provided detail information and diagrams of their circuit breaker design. This was compared to circuit breakers available from Blue Sea Systems, and was able to determined that Blue Sea Systems circuit breakers would fit the BEP Marine DC Circuit Breaker panel. The notable difference was the terminal ring size on BEP Marine/Airpax DC circuit breaker was a #8mm, while the Blue Sea Systems circuit breakers terminal ring size was a #10mm. Order and received the following replacement Blue Sea Systems circuit breakers.
| P/N | Item | Q | Each | Total |
| 7220 | Single Pole Magnetic AC/DC Circuit Breaker 30A Black | 1 | $19.61 | $19.61 |
| 7216 | Single Pole Magnetic AC/DC Circuit Breaker 25A Black | 1 | $19.61 | $19.61 |
| 7208 | AC/DC A-Series Single Pole Circuit Breaker, 15 Amp, Black | 2 | $16.39 | $32.78 |
| 7204 | AC/DC A-Series Single Pole Circuit Breaker, 10 Amp, Black | 1 | $16.39 | $16.39 |
| 7200 | AC/DC A-Series Single Pole Circuit Breaker, 5 Amp, Black | 1 | $16.39 | $16.39 |
| 8035 | Blue Sea Systems, Circuit Breaker Mounting Screws, Fits A Series and C Series | 1 | $2.05 | $2.05 |
| $106.83 |
In order to change the broken circuit breakers, the BEP Marine Model 905DV DC Circuit Breaker panel needed to be removed from it's installed location below the chart table desk. Upon removing the panel mount screws, discovered there was not enough slack in the wiring to pull the panel forward to change the broken circuit breakers. This meant the wiring would need to be removed from the panel - this was equivalent to opening Pandora's box, due to the rat's nest maze of wiring and the discrepancies discovered.
Starting at the top of the DC panel each wire was removed one-by-one. Numerous wire crimps to ring terminals were found with most of the wire strands broken off, it was just a matter of time before they completely broke off. The majority of the wire terminals and the wires were not marine rated and would need to be replaced. Numerous wires were discovered not connected to anything. Numerous wire to terminal connections had excess insulation stripped away resulting in exposed wires with the potential for shorting out. The excess use of butt splices to connect wires was absurd. Probably the most telling example was a wire tee connection - the insulation was stripped away from the wire; wires twisted together; a touch of solder applied to hold the connection; and no insulation was applied to protect the connection.
With the wiring remove from the DC panel, the circuit breakers were easily replaced. The wiring discrepancies discovered are already encompassed with To Do List item A0185 - Redesign complete 12 VDC system installation. To still have DC power for fans and lighting, make-shift wire jumpers were connected to the one 12-volt battery still aboard.
