Electrical

Alternator

Powerline Model 23-11
120 Amps
Date Code: MAY-22-03
Serial No.: A11040
Purchased: 7/03

Spare alternator

Powerline Model 23-11
120 Amps
Date Code: 60297
Serial No.: A06856

14 pole alternator puts out a 50% duty cycle on the R terminal (white wire) -- 7 pulses per revolution (tach takeoff not used on Willow)

The alternator ratings are based on SAE standards -- 6,000 RPM alternator speed and 78°F temperature. The maximum temperature is 300°F. The efficiency of a high-output alternator is around 49%. An automotive alternator is only around 30% efficient (Rodney Knelly at Hehr)

Pulley is a Powerline Model No. 8-603, 2.2" diameter. Crank shaft pulley is 4.75" diameter. (2.16 ratio)

The original pulley (8-609) measured at 2.7" x 7/16". The new pulley measures 2.2" x 1/2".

Belt is a Gates Green Stripe (notches on belt), No. 9412 (12.5/13mm x 1050mm) or NAPA 25-10455 (25 9412). On the belt is written 13A1040. The belt lifetime is between 300 and 400 hours. Replace every 300 hours.

To remove the pulley nut, an impact wrench (rented) is magic. The nut is 15/16". Without an impact wrench, use a 5/16" hex key inserted into the center of the shaft to lock it and then use a wrench on the nut. The nut should be tightened to around 50 ft-lbs.

Defender carries parts for Powerline

Recommended alternator filters from Powerline: Electrocube (800-516-1112) G2438 fluorescent light filter on the field, G2418-150 on the power output.

Repair kit 13-113 (list $110). Rebuild the alternator every 3,000 hours. If the boat is left standing in a salty environment, the alternator may not output a voltage. If so, sand the slip rings to get rid of corrosion, sand the brushes, and reassemble. The alternator does not have any type of over-temperature current fold-back internal to it.

Rebuilt old unit that failed after about 2,000 hours. The repair place said that the bearings overheated due to too tight of a belt. They suggested tightening the belt just enough to stop the pulley from being able to turn when gripped with my hand. Then, run the engine until hot and adjust the belt again. The old unit is now a spare onboard.

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Alternator Filter

Installed a low-pass LC filter from Newmar. Part number 150-A This filter is supposed to remove alternator noise from the radios.

Batteries – 12V

Battery cable between house batteries is 2/0 AWG Ancor.

* Approximate, depending on battery technology, manufacturer, etc.

Reserve Capacity = minutes to drain 25 amps @ 80ºF to 1.75V/cell (10.5V)

Amp-Hours = number of amps discharged for 20 hours @ 80ºF to 1.75V/cell (10.5V). To calculate Amp-Hours capacity at a different discharge rate, use

        C_R = R * H * (C_H / (R * H))^P

where

CR	Amp-Hour capacity at the new discharge rate
H	Hours that the capacity was specified at
CH	Amp-Hour capacity at the specified discharge rate
R	Discharge rate
P	Peukert's exponent (about 1.24 for flooded lead-acid, 1.12 for AGM)

Amp-Hours = (Reserve Minutes * 0.4237) + 14.5 (calculated from an Excel spreadsheet)

from Trojan Battery User's Guide

Batteries – Dry Cell

                                                                * Rechargeable

Battery Combiner

Hellroaring Technologies, Inc. Model BIC-75150A S/N A01C3337 (5/01). This is wired to isolate the starting battery and the boat runs everything on the house battery. The starting battery is only used for starting the engine. Replaced the first unit that failed (internal MOSFET blown).

Electrical Panel

Made by Bass Products, Inc.

Panel is 791004A

Light is 791001

20 DC breakers arranged 2 x 10 and 5 AC breakers

Circuit Breakers:

Airpax, 8641 Line, Model UPG6-1-52-103-91 (Black Handle)

Carlingswitch Model  AA1-X0-00-905-XD1-C (Black Handle)

Installed a Galvanic Isolator on the AC ground (4/1999).

The Lectra/San circuit breaker (75 amps) is located in the engine compartment on the port side.

Pump Panel

Located under galley sink. This controls the pumps (and the fuses for) the refrigeration pump, the freshwater pressure pump, and the galley seawater pressure pump. The panel was custom made by M & I Systems based on my .DXF design.

FB3 - Fuse Block 3 (Starboard)

Other Fuses

Galvanic Isolator

Installed behind electrical panel. From Yacht Corrosion Consultants (Professional Mariner) Zinc Saver: Installed 1999.

Lighting

Lamp Base Information

T-3¼ Incadescent mini bayonet-base lamps for engine instrument gauges:

I had a problem with the 1893 lamps turning black (silver?) just running the instruments overnight. I installed a diode in-line with the positive feed, which dropped the voltage 0.7V and stopped the lamp problem.

To convert from candela to lumens:

Lumens = Candela * 2 * π * (1 - cos(θ/2))

θ in radians.

The following is the section from the COLREGs about lamp brightness:

8. Intensity of lights

(a) The minimum luminous intensity of lights shall be calculated by using

the formula:

I = 3.43 x 106 x T x D2 x K-D

where:

I is luminous intensity in candelas under service conditions.

T is threshold factor 2 x 10-7 lux.

D is range of visibility (luminous range) of the light in nautical miles,

K is atmospheric transmissivity. For prescribed lights the value of K

shall be 0.8, corresponding to a meteorological visibility of

approximately 13 nautical miles.

Lightning Protection

• The tip of the lightning rod should be at least 10" above what it is designed to protect. In addition, all other objects should fall under a protective 90° cone from the tip.
• Use a rounded tip rod with a radius of curvature between 3/16" and 1/2".
• Aluminum or stainless steel are fine.
• A 3/8" rod with a flattened attachment point to the mast will suffice.
• The bottle brush devices aren't any more effective than a plain, rounded rod.

From Dr. Charles Moore, New Mexico Tech

The rig is bonded to underwater through the engine (at least for now). Green 6 AWG wire used throughout (2002).

Noise (EMF) Reduction

To reduce pump noise in the refrigeration pump:

Opened up the pump and put a 0.1 µF cap across the power leads at the brushes. Also, put a reversed-bias diode across the capacitor to kill back-EMF. Also, connected the ungrounded metal case to the power supply ground.

To reduce refrigeration hum in SSB:

Grounded unused conductors in thermistor lead to the metal chassis ground of the refrigeration unit.

Towed Water Generator

Hamilton Ferris

Prop - plastic 8¼" x 5" three-bladed prop (OMC 386587, $50).

Diodes - 1N1200A 12A, V_f 0.95V @ 5A 25°C. Can be replaced with IR 63CPQ100, 100A, V_f 0.6V @ 5A 25°C

Tricolor/Anchor Light

Orca Green Marine, model LXTA-P. This is an LED-based combo light at the top of the mast. Measured current @12V of 0.4A for either one being on. The anchor light turns off at sunrise with a built-in photocell in the green sector.

The light has a waterproof connector on the bottom. The mating cable is a Conxall Nano-Mizer 603ST2. The included cable has 24 AWG wires. The contacts are gold-plated.

My original unit failed with water intrusion. OGM replaced it under warranty 12/2008.

Wiring

B - black, R - red, P - purple, Br - brown

All green wires are for bonding. The 6 AWG wire is for lightning bonding and 8 AWG wire is for cathodic bonding.