Powerline Model 23-11
Date Code: MAY-22-03
Serial No.: A11040
Powerline Model 23-11
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)
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.
Installed a low-pass LC filter from Newmar. Part number 150-A This filter is supposed to remove alternator noise from the radios.
Reserve Cap. (min)
|Starting Battery||Group 27||
|House (starboard settee -- 4x 6V)||Trojan||T-105||
Battery cable between house batteries is 2/0 AWG Ancor.
|Group 24||11½"||7"||10"||50||70||3/8"(+) and 5/16"(-)|
|Group 27||12¾"||7"||10"||60||90||3/8"(+) and 5/16"(-)|
* 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
CR = R * H * (CH / (R * H))P
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
|Flashlight - Black||
|Flashlight - Mag-Lite, black||
|Flashlight - Dive light||
|GPS - Garmin||
|Penlight - Black w/ red lens||
|Penlight - Mag-Lite, blue||3||AA*||2|
|Dinghy navigation lights||2||AA*||4|
|Flashlight - Rocky LED||2||AAA*||3|
* Rechargeable available
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).
Made by Bass Products, Inc.
Panel is 791004A
Light is 791001
20 DC breakers arranged 2 x 10 and 5 AC 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.
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.
FB1 - Fuse Block 1 (Port Top)
FB2 - Fuse Block 2 (Port Bottom)
|FB3-1||AGC||2A||Ideal Regulator shunt protection|
|FB3-2||AGC||20A||Power to Ideal Regulator|
|FB3-4||AGC||2A||Ideal Regulator shunt protection|
|SSB RT Head(1)||AGC||5A|
|SSB RT Head(2)||AGC||5A|
Installed behind electrical panel. From Yacht Corrosion Consultants (Professional Mariner) Zinc Saver: Installed 1999.
|Bow nav light||Aqua Signal||Series 40||25W 90002-7||T-8/BAY15D|
|Stern light||Aqua Signal||Series 40||10W 90005-7||T-8/BAY15D|
|Tachometer||IA62995 (1 or 2 candle-power, wedge base)|
|Engine Gauges||1893 (Dialight LED p/n 585-4213 ultra-red $6, LedLight p/n BF321CR3K-14V-P). Can also use 756, 1813, 1889, or 1892 lamps (>13V).||T-3¼/BA9S||0.33|
|Steaming Light||Perko||964 DP CHR||71 DP CLR (10W, 8CP)|
|Dome light - nav station||ABI||7"||White: 20W halogen (G4), pins 0.184" apart, height 0.882
Red: 10W halogen
|G4||Replaced white light with Sensibulb LED light|
|Spreader Deck Lights||??||??||GE 4411-1 35W 300 hours|
|Cabin reading lights||??||??||90 (6CP), 1004 (15CP, 0.94A)||G-6/BA15D||0.58|
|Chart light||Hella||Osram 3386X or Trifa 1639||BA9S||0.50||85 lumens|
|Tricolor/Anchor||Orca Green Marine||LXTA-P||LED||n/a||0.50||Photocell on anchor light (replaced 12/2008)|
|BA15D||Bayonet, double contact||15 mm|
|BA15S||Bayonet, single contact||15 mm|
|BA9S||Miniature bayonet, single contact||9 mm|
|BAY15D||Bayonet, double contact, indexed||15 mm|
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
I = 3.43 x 10
I is luminous intensity in candelas under service conditions.
T is threshold factor 2 x 10
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
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).
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.
Bilge Pumps (LBP-Lower Bilge Pump, UBP-Upper Bilge Pump). Located under floorboard near engine inlet strainer.
|Wire 39-R||TB1-5||UBP bilge switch|
Prop - plastic 8¼" x 5" three-bladed prop (OMC 386587, $50).
Diodes - 1N1200A 12A, Vf 0.95V @ 5A 25°C. Can be replaced with IR 63CPQ100, 100A, Vf 0.6V @ 5A 25°C
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.
|AP||Sheath||14||Circuit breaker "Autopilot" to autopilot|
|B0||B||6||Ground from battery charger to Link 2000 shunt|
|B1||R||6||Positive from battery charger to House Bank|
|B2||R||6||Positive from battery charger to Starting Battery|
|10||R||8||Starting Battery to fuse block FB2-3|
|11||R||8||House Bank to fuse block|
|12||R||10||Fuse block to Battery Combiner "C" (Starting Battery)|
|13||R||10||Fuse block to Battery Combiner "A" (House Bank)|
|14||R||10||Battery Combiner Ground to Fuse block|
|15||R||16||Fuse block to ground on sense resistors|
|16||R||6||Circuit breaker "Radio" to SSB/VHF|
|17||B||6||SSB/VHF to Link 2000 ground shunt|
|18||B||2/0||Engine block to Link 2000 ground shunt|
|19||R||2/0||Positive from House Bank to distribution stud|
|20||B||2/0||Negative from House Bank to Link 2000 ground shunt|
|21||R||2/0||Starter bank +|
|22||B||2/0||Starter bank -|
|23||R/B||16||Fuse box to fresh water pump|
|24||R/B||16||Fuse box to refrigeration pump, icebox fan|
|25||R/B||16||Fuse box to seawater pump|
|26||R/B||16||Power to fuse box for pumps|
|29||R||2||House + to Lectra/San circuit breaker|
|35||R/B||12||Lower navigation lights|
|36||P||16||Engine alarm connection|
|38||R/B||16||Fuse box to lower bilge pump|
|39||R/B||16||Fuse box to upper bilge pump|
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.