Initial Inspection - Electrical Systems

 

 

 

Alternating Current (AC)  Electrical System

 

Indra's advertisement was very vague about the AC electrical system and only stated a shore power battery charger and a 12V/240VAC inverter were aboard.  Old documents found aboard from previous owners in the past indicated this boat at one time did have a 110 VAC electrical system with circuit breaker panel, battery charger, hot water heater, and AC outlets.

Inspection of Indra revealed there was no exterior mounted AC inlet plug installed for the hook up of shore based electrical power - power was brought aboard by 240 VAC electrical extension cords routed up into the boat and through the companionway.  Below the companionway steps, a GYS CT180 Battery Charger was found and the output leads were still connected to the 12 volt GEL type, ships batteries.  A manual was not located for this discontinued (no longer made) battery charger, however obtained a old detailed sales brochure from internet searches.  Manufacture’s literature for this battery charger stated it is only for use with lead acid batteries with liquid electrolyte; it cannot provide the charge requirements specified for GEL batteries.  Numerous battery websites stated, “Never charge a sealed (GEL cell) battery with a wet battery charger.” and “One disadvantage of GEL cells is that they must be charged at a slower rate to prevent excess gas from damaging the cells. They cannot be fast charged on a conventional automotive charger or they may be permanently damaged.”

Added to the To Do List:

  • A0174 – Delete GYS CT180 battery charger.
  • A0175 - Design and install 110 VAC electrical system with marine rated battery charger/inverter.

 

A review of the interior revealed a 110VAC electrical output located on the starboard side, above the V-berth cabinet drawers.  As picture below reveals, the 110VAC electrical output had no wiring connections.  Another 110VAC electrical output was located on the forward part of starboard settee, and it two had no wiring to it.

Added to the To Do List:

  • A0176 – Remove unused AC outlets and any associated wiring.

 

A PACO 800 Watt Modified Sine Wave Power Inverter (12 VDC to 240VAC) was installed in the navigational  desk cabinet.  The manual from this discontinued (no longer made) inverter was obtained from the internet.  A extension cord plugged into the inverter then routed power to a two electrical outlet panel mounted at the navigational desk to provide 240 VAC power - suspect used for the onboard laptop computer and printer.  The wiring to the inverter originated from the battery bank and did not have inline fuse protection.

Added to the To Do List:

  • A0177 – Delete PACO power inverter and associated wiring.

 

 

Direct Current (DC) Electrical System

The master battery switch panel was located just aft of the navigational station and consisted of three BEP 701-PM panel mounted battery switches - with house and start battery switches set to On and emergency parallel switch set to Off.  Underneath and just aft of the navigational station was a BEP 24 switch circuit breaker panel with a BEP 600-DCM battery monitor and BEP 600-TLM2 tank monitor.  The 12 VDC circuit breaker (CB) panel had the freshwater pump CB taped over in the Off position; and the stern light and 12v outlets CB heads were broken off.

Added to the To Do List:

  • A0178 – Obtain replacement 12 VDC circuit breakers.

Removed the aft starboard berth floorboards to gain access to the battery bank.  The engine start battery was a Motolite Solar Master Deep Cycle 70 amp hour, lead-acid battery.   Four Toyama model NPG225-6, 6-volt 225 amp hour GEL batteries were combined to make a 12 volt 450 amp hour house battery bank.

The Toyama model NPG225-6 battery is the same as the MCA Battery Manufacture Company model FCDG6-225 battery.   There was no fuse protection on any of the positive output battery cables or wires.

A voltage check of the individual batteries did not yield favorable results.  These batteries were still connected to the solar charger and to obtain low voltage readings meant the batteries were all suspect.

Added to the To Do List:

  • A0179 – Redesign and rewire DC cables so that only one connection to the batteries exists.
  • A0180 - Add inline fuse protection within 12 inches of battery terminals.
  • A0181 - Determine health and capacitance of batteries.

 

Tracing the 12 VDC positive output cables from the battery bank discovered the main protective fuse circuit - however, its ANL fuse was not installed and was bypassed with a wire jumper.  Improper fuse protection of electrical circuits was one of the principal causes of boat fires and related deaths per many internet website sources.

Added to the To Do List:

  • A0182 – Add proper protective fuses to 12 VDC positive battery output circuit.

 

The negative cable return to the battery was connected to a DC shunt to indicate battery amperage use.  As picture below reveals, an excess number of wire and cables are connected to the DC shunt.  Also one side of the shunt terminal is a bolt while the other side is modified with a threaded terminal with nut to allow more connections than practical/recommended.  As a negative terminal bus bar was not installed aboard or in this circuit, the DC shunt is the also incorrectly fulfilling this role.

Added to the To Do List:

  • A0183 – Obtain replacement DC shunt and negative terminal bus bar.
  • A0184 - Redesign and rewire negative return cables to the batteries.

 

 

Main DC Circuit Breaker Panel

 

The BEP 12 VDC main circuit breaker panel was inventoried of systems labels and circuit breaker ratings.  These circuit breaker ratings were then compared to the requirements of the system they were connected to, as follows:

 

  • Panel Lights  - 5 amp

This 5 amp circuit breaker provides power to main circuit breaker panel edge/back lights, BEP 600-DCM battery monitor, and BEP 600-TLM2 tank monitor.  All of these are specified per their installation manuals to have 1 amp fuse protection on separate circuits. The amperage rating of this circuit breaker is not correct for its current use.

  • Riding Light - 15 amp

This 15 amp circuit breaker provides power to a Aqua Signal Series 25 All-Round Navigation Anchor Light mounted atop the mast with a 10 watt bulb.  Based on watts/volts = amperage, then 10/11 = ~1 amp fuse size required.  The amperage rating of this circuit breaker is not correct for its current use.

  • Navigation Lights - 5 amp

This 5 amp circuit breaker provides power to two Hella Marine 2984 series 2 NM Navigation Lamps mounted at the masthead pulpits with a 25 watt bulbs.  Based on watts/volts = amperage, then (2x25)/11 = ~4.5 amp fuse size required; which would be correct for this use.  However, the 25 watt incandescent bulbs were replaced with LED bulbs with a total 1 amp protective fuse requirement.  The amperage rating of this circuit breaker is not correct for its current use.

  • Strobe Light - 10 amp

This 10 amp circuit breaker provides power to a undetermined manufacture white strobe light with unknown bulb wattage.

  • Spreader Light - 15 amp

This 15 amp circuit breaker provides power to two Sea-Dog 12 volt 35 watt sealed beam bulb spreader lights.  Based on watts/volts = amperage, then (2x35)/11 = 6.4 amp fuse size required.  The amperage rating of this circuit breaker is not correct for its current use. Additionally, the port side spreader light is broken off with wiring ends exposed - this circuit should not be used until wiring is confirmed isolated or new light installed.

  • Auto Pilot - 10 amp

This 10 amp circuit breaker provides power to a Raymarine ST4000 Plus autopilot and its installation instructions specifies use of a 12 amp protective fuse.  The amperage rating of this circuit breaker is under rated and not correct for its current use.

  • Galley LT - 15 amp

This 15 amp circuit breaker provides power to multiple LED light fixtures in the galley and cabin area.  As these circuits are LED based, it is suspected the 15 amp circuit is not properly sized for the LED amperage use.

  • Cabin Lights FWD - 15 amp

This 10 amp circuit breaker provides power to multiple LED light fixtures in the forward cabin, hallway, and head areas.  As these circuits are LED based, it is suspected the 15 amp circuit is not properly sized for the LED amperage use.

  • Sole Lights - 15 amp

This 10 amp circuit breaker provides power to LED lights at the floor area of the cabin.  As these circuits are LED based, it is suspected the 15 amp circuit is not properly sized for the LED amperage use.

  • 12V Outlets - 5 amp

This circuit breaker's head is broken off and needs to be replaced.  This 5 amp circuit breaker provides power to at least four 12 volt outlets; one at the forward side of the starboard settee; one at navigation station, one on the engine start panel, and one at V-berth area.  The 12 volt outlet is rated for a maximum of 15 amps use and as a minimum should have a equivalent sized circuit breaker.  The amperage rating of this circuit breaker is under rated and not correct for its current use.

  • Freshwater Pump - 15 amp

This circuit breaker was taped over in the Off position with note to not use.  As indicated in Initial Inspection – Water System, this 15 amp circuit breaker provides power to a Shurflo Smart Sensor 4.0 diaphragm water pump and its installation instructions specifies use of a 15 amp protective fuse.  The amperage rating of this circuit breaker is correct for its current use.

  • Galley Frig - 25 amp

This 25 amp circuit breaker provides power to a Isotherm 3751 Automatic Start Up (ASU) water-cooled Self Pumping (SP) refrigeration unit and its installation instructions specifies use of a 15 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.

  • Depth Sounder - 10 amp

This 10 amp circuit breaker provides power to a Navman Multi 3100s display with depth and speed transducers and its installation instructions specifies use of a 1 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.

  • Instruments - 5 amp

This 5 amp circuit breaker provides power to a Navman Wind 3150 display and wind transducer and its installation instructions specifies use of a 1 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.

  • Stern Light - 5 amp

This circuit breaker's head is broken off and needs to be replaced. This 5 amp circuit breaker provides power to a Aqua Signal Series 25 Classic Stern Light mounted at the stern with a 10 watt bulb.  Based on watts/volts = amperage, then 10/11 = ~1 amp fuse size required.  The amperage rating of this circuit breaker is not correct for its current use.

  • Tri Light - 10 amp

This 10 amp circuit breaker provides power to a Aqua Signal Series 40 Tri-Color Navigation Light mounted atop the mast with a 25 watt bulb.  Based on watts/volts = amperage, then 25/11 = ~3 amp fuse size required.  However, the 25 watt incandescent bulb was replaced with a LED bulb with a total 1 amp protective fuse requirement.  The amperage rating of this circuit breaker is not correct for its current use.

  • Diesel Heater - 10 amp

As indicated in Initial Inspection – Diesel Heater,  this 10 amp circuit breaker provides power to a ECCO model 1LM12 diaphragm fuel pump and its installation instructions specifies use of a 3-5 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.  Additionally, the fuel pump inlet fitting is broken off and fuel line plugged - this circuit should not be used until pump is replaced and fuel line connected.

  • LPG Control - 10 amp

As indicated in Initial Inspection – LPG System, this 10 amp circuit breaker provides power to a BEP Marine model VR2 12 volt gas solenoid and its installation instructions specifies use of a 2 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.

  • Spare - 15 amp

This 15 amp circuit breaker is not connected to any wiring.

  • Compass Light - 10 amp

This 10 amp circuit breaker provides power to a Ritchie Navigator Flush Mount Compass mounted in the cockpit well for its night light and its installation instructions specifies use of a 1 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.

  • Multiplexer - 20 amp

This 20 amp circuit breaker provides power to a PACTOR SCS-PTC-IIE modem mounted at the navigation station and its installation instructions specifies use of a 1 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.

  • SSB - 30 amp

This 30 amp circuit breaker provides power to a Icom IC-718 HF radio mounted at the navigation station and its installation instructions specifies use of a 25 amp protective fuse.  The amperage rating of this circuit breaker is not correct for its current use.

 

The following components were installed and not identified on the BEP 12 VDC main circuit breaker panel.

  • ICOM M-45 VHF Radio - 10 amp fuse required.
  • Furuno Model 1832 radar - 10 amp fuse required.
  • Furuno GP-32 GPS Navigator - 1 amp fuse required.
  • Sea-Me Radar Signal Enhancer - 0.5 amp fuse required.
  • Sony FM/AM Digital Radio CD Player - 10 amp fuse required.
  • Dickinson Newport diesel heater 12 volt electric fan - 1 amp fuse required.
  • Lofrans Windlass Control Line Fuse - 5 amp fuse required.

Based on the above use of circuit breakers, the BEP 12 VDC main circuit breaker panel was being used more as a On/Off switch panel than for circuit fuse protection.

Added to the To Do List:

  • A0185 – Redesign complete 12 VDC system installation.  Ensure each wire is rated for the amperage it is intended to support and proper rated fuse protection is implemented.  Remove all unused wiring.

 

 

 

Anchor Windlass

A Lofrans Tigres windlass was installed at the bow and manuals were obtained from manufacture's website.  A single Lofrans foot switch (P/N 600012) was mounted on the deck just aft and starboard of the windlass; it functions in the UP position only.  A Lofrans Type L control switch (P/N 404728) was installed on the engine start panel, just inside and starboard of the companionway entrance.  A Lofrans control box (P/N 600018) was mounted under the V-berth in the stowage area.  Per previous owner's logs, the windlass was totally rebuilt in March 2014 and a spare foot switch was aboard.  The manufacture's manual has detailed periodic maintenance requirements and all were due to be accomplished; but on hold, until oil and parts were obtained.

Added to the To Do List:

  • A0186 – Obtain Lofrans Maintenance Kit for Tigres (#LWP72050).
  • A0187 - Obtain Lofrans motor housing to gear box flat rubber gasket seal (#LWPHP0095).
  • A0188 - Obtain sufficient quantity of SAE90-140 gearbox oil.
  • A0189 - Perform Lofrans windlass periodic maintenance requirements per instruction manual.

 

From the Lofrans control box the windlass electrical cables were run directly aft along the centerline, under the floorboards, to the starboard aft berth area.  The cable was connected to a Blue Sea 100 amp circuit breaker P/N 7102.  The Lofrans windlass installation instructions specify the power line circuit breaker should be of 125 amp rating, not the 100 amp breaker in use.  The circuit breaker input terminal stud had corroded and broken off.  The cable with the nut still attached is from the engine start battery positive terminal with no inline fuse protection - very lucky this cable did not contact any metal, short out the battery, and potentially cause a fire.

The Blue Sea 100 amp circuit breaker was located in the aft starboard berth area and was mounted to the inboard wall underneath a wood box enclosure that required the removal of three screws for access.  The Lofrans windlass installation manual states, "This Lofrans circuit breaker protects the power line from short circuit and the windlass motor in case of overheating. It must be installed in an accessible place to be promptly reactivated when it trips.  It can be also used to isolate the windlass from the remote controls as we strongly suggest to avoid accidental engagement."  The installation of the circuit breaker under this wood box enclosure prevents ready access and violates the manufacture's installation instructions.

From the circuit breaker, the cable went further aft and was connected directly to the Motolite Solar Master Deep Cycle 70 amp hour engine start battery, with no inline fuse protection.  The Lofrans windlass installation manual specifies the minimum battery size for this 1500 watt/125 amp windlass to be connected to should be 250 amp hour, not the current 70 amp hour battery it was connected to.  It was suspected that the previous owners supplemented the engine start battery amperage by running the engine with windlass use, which had a 100 amp alternator.  However even these extra 100 amps, of which less than 100 amps is output, is still not sufficient.   The manufacture's manual cautions that inadequate amperage capacity can result in excessive wear and damage to the windlass.

The windlass electrical power cables were made by Triangle Cables and were coded FP150 1000V.

Internet research revealed the FP designation by Triangle Cables indicates that these cables were manufactured for Telecommunications, Batteries, and UPS use - they are not marine rated.  Triangle Cables does make certified cables for marine use and they are designated as their BB series of cables.  One significant difference between the FP and BB series is the FP series is plain copper, while the BB series is tin plated copper to enhance corrosion protection in a marine environment.  The 150 number in FP150, is the metric size designation of the wire core.  Based on the entire length of cable run and expected 125 amp current, US electrical wire tables recommend a 4/0 AWG cable size for this installation.  The 4/0 AWG cable size is equivalent to a metric size designation of 107.2, so the Triangle Cables FP150 cable is more than adequate in electrical amperage conducting capacity.  The recommendations from many internet sites and books clearly advise that all wiring used in a marine environment be certified for that use and be of the tin plated copper wire type.  This discrepancy in cable type and its resolution will be determined by if the existing cable can be relocated to accommodate the new location of the circuit breaker in an accessible location and change of battery connections.  If any of this cable is retained, the terminal ends will be inspected for corrosion wicking up the stranded copper core and heat shrink reapplied to terminal ends to minimize the entrance of corrosive moisture.

Closer inspection of the Lofrans control box wiring revealed that plastic automotive type 6mm (0.25 inch) faston terminals were used instead of marine rated terminals with appropriate heat shrink.  The blue color plastic covering on these terminals indicates the recommended sizes of wire it is to be used with.  Blue is for 16 - 14 AWG wire or in metric 1.5 - 2.5mm diameter wire.  Each of the wires depicted below is 16 AWG or 1.31mm.  One blue terminal has two black wires connected, for a combined size of 2.62mm or greater, which means the next larger size terminal, yellow 2.62-6.64mm, should have been used.  As these plastic automotive type faston terminals are not appropriate for a marine environment, all will be replaced with appropriate marine rated terminals with heat shrink, both sides of the terminal connection cleaned, and a dielectric grease applied to minimize corrosion.

Added to the To Do List:

  • A0190 – Obtain Lofrans windlass 12 VDC line circuit breaker of correct amperage rating.
  • A0191 - Rewire Lofrans windlass positive and negative windlass cables to main house bank batteries with proper inline fuse protection.

 

Sony AM/FM/CD Player Radio

A standard automotive Sony FM/AM Digital Radio CD Player model CDX-GT710HD was installed at the navigation station and the manual was obtained from the internet.  Four speakers were installed in the cabin area.  When radio was turned on discovered sound came from only one speaker, the one closest to the navigation station.  Inspection of the three other speakers revealed they had no wiring connected.

Added to the To Do List:

  • A0192 – Determine if radio speakers are operable and rewire circuit.

 

 

Solar Power System

Two Helios 100 watt solar panels on adjustable mounts were attached to stainless steel railings on the boomkin.  Their cables were routed down both the port and starboard side and entered the hull through cable adapters to the port side lazaret where a ProStar-15 solar charge controller was mounted.  The output of the controller to the batteries was two small gauge wires connected together (paralleled) for both the positive and negative outputs.  This practice is a work around used when the proper gauged wire size is not available/used.  In this case, two 12-gauge wires were used instead of the recommended 8-gauge wiring based on 15 amp maximum output and combined length of both positive and negative cable runs.  The use of two 12-gauge wires does not provide the proper cable ampacity for this 15 amp circuit.  The wires were then connected to the batteries with no inline fuse protection on the positive input.

Added to the To Do List:

  • A0193 – Install proper gauged wire with fuse protection for solar controller output.

 

 

Ritchie Navigation SuperSport SS-2000 4.5 inch Flush Mount Compass

 

In Indra's forward cockpit well, a Ritchie SuperSport SS-2000 compass was installed with a protective white cover ( Ritchie part number N-203-C ).  Based on prior pictures, this was a new installation location for the compass and a compensation check of the compass was added to the To Do List.  A compensation check of the compass was added to the Periodic Maintenance List as a annual requirement, as this was also recommended in the manual. The Ritchie SuperSport SS-2000 compass is still being manufactured and price check at Defender website lists it for $349.99.  Manuals and spare parts are still available at Ritchie Navigation website.  Per Ritchie Navigation Service Manual, introduction section, the serial number's first two digits represent the year manufactured, so this compass was originally built in year 2005.

The Ritchie SuperSport SS-2000 compass is equipped with 12-volt night lighting consisting of two green LEDs and the manufacture recommends use of a 1 amp protective fuse.  The compass wiring was incorrectly connected to a 10 amp circuit breaker on the main 12-volt DC panel.  Check of the compass LED lighting revealed it was not functioning.

 

Added to the To Do List:

  • A0218 – Perform compensation check on Ritchie SuperSport SS-2000 compass.
  • A0219 - Obtain replacement LED light assembly and mount gasket for Ritchie SuperSport SS-2000 compass.
  • A0220 - Rewire Ritchie SuperSport SS-2000 compass 12-volt night lighting to include 1 amp protective fuse.