Basic design for Catalina 34 rewiring project

This document attempts to capture some of the key elements of the

electrical upgrade project for a Catalina 34 Mk1. The specs and
suggestions below are my contributions as an electronics engineer with
boating experience but do not re!ect the experience and expertise of
a marine electrician. They should therefore be reviewed by a licensed
marine electrician before implementation.
12 V power systems
"e#tting will include two battery banks named $%ouse&'attery( and
$)ngine&'attery( supplying a $%ouse&*witched&'us( and an $)ngine&
*witched&'us( connected with a three switch con#guration consisting
of a battery&style +,-+.. switch for each bank and 'us&Tie /+,-+..0 to
tie the two load buses together for emergencies where one battery
bank is dead and it is desired to operate systems /electronic or engine0
from the alternate battery bank. 1etails below.
Batteries and Battery banks
The )ngine bank will consist of a single low&maintenance !ooded
battery in a new location under the aft berth. 2t will power the $)ngine&
'at&'us( through a battery fuse su3cient to carry starter current. The
)ngine&'at&'us feeds an +,-+.. battery&style switch that powers the
$)ngine&*witched&'us(.
The %ouse bank will consist of four T145 67 8859hr !ooded batteries
connected in series&parallel. The bank will connect to the %ouse&'at&
'us through a fuse su3cient to power the 8kw in7erter or to carry
starter current in the e7ent that it is called on to do so through the 'us&
Tie switch. The %ouse&'attery bank will be in the existing battery
locker. The four batteries are a tight #t therefore it will be critical to
plan the space carefully for any switches bus bars etc. to ensure the
clearances are maintained and that the batteries can be remo7ed for
replacement without disassembling wiring de7ices.
The %ouse&'at&'us will feed a battery&style +,-+.. switch that feeds
the $%ouse&*witched&'us(.
The %ouse&'attery bank will ha7e a negati7e lead current sense shunt
for the multi&meter in the 364 :anel so that 9;; current into and out of
the %ouse&'attery bank is sensed.
6-1<-8414 re7 :age 1 of =
Emergency Bus-ie !aka Cross-Connect"
There will be a battery&style +,-+.. switch named $'us&Tie&*witch(
that can connect the )ngine and %ouse load buses together. This will
allow one to>
1. *tart the engine from the %ouse&'attery bank
/turn +.. the )ngine&'attery&*witch then turn +, the 'us&Tie
switch0.
&or&
8. +perate electronics such as the ?%. from the )ngine&'attery
/turn +.. the %ouse&'attery&*witch then turn +, the 'us&Tie&
*witch0.
The 'us&Tie&*witch will be located near the )ngine 'attery and its
switch in the aft cabin.
Battery C#arging
The existing alternator is being replaced with a new ;, =4amp unit
con#gured for external regulation. The alternator output will be
connected directly to the %ouse&'at&'us to ensure that the alternator is
loaded e7en if the %ouse&'attery and-or )ngine&'attery switch
inad7ertently gets turned o@ with the engine running. There will also
be (optional - not decided yet) a ser7ice disconnect switch at the
alternator to disconnect it during ser7icing. This switch should be near
the alternator in the engine compartment and appropriately labeled.
The alternator will be regulated by an external 'almar MC&614
regulator to be mounted near but outside of the engine compartment
in a location-orientation conduci7e to reading the diagnostic display.
2deally the factory&pro7ided 54( wiring harness can be used. 2f the 'A
and #eld wires need to be extended they should be changed to hea7ier
gauge for their entire length. The external battery 7oltage sense wire
should be run to the %ouse&'at&'us bus bar so that the regulator
recei7es accurate battery 7oltage info. The unit should be con#gured
with both alternator and battery temperature monitoring as well as an
added switch to enable $*mall )ngine Mode.(
1
*witch should be well&
labeled located near the regulator and be owner&accessible for use
when needed.

The 'attery temperature sensor option should be
connected to the battery in the %ouse&'attery bank deemed likely to
be the warmest.
1
This switch is optional and should be discussed with owner. The most likely use case
would be to temporarily reduce alternator load if belt shedding problems de7elop
until a longer term solution is put in place. .or the cost of a simple switch it seems
worthwhile.
6-1<-8414 re7 :age 8 of =
Charging of the )ngine&'attery will be accomplished by a Bantrex
)cho&Charger connected to draw from the %ouse&'at&'us and feed the
)ngine&'at&'us thus charging the )ngine battery whene7er the engine
is running or the 9C battery charger is on.
The existing 1157ac :roMarine :rotech1884i 84 amp battery charger
will be replaced with a new :ro,autic 1844: along with its optional
remote panel. The charger will connect to the %ouse&'attery bank
using one of its three outputs fused at the battery end.
8

$ain %anel
,ew 'lue *ea 364 :anel is di7ided into four logical columns and will
handle following>
10 115 ?9C> ;eft column> *hore :ower input. *ince the panel is within
14C of the shore power receptacle the 8&pole 34 amp Main *hore
:ower 'reaker will be in the panel /upper left module of panel0. 2t will
include a "e7erse :olarity indicator /but not be );C2 eDuipped due to
nuisance trip concerns0.
The Main *hore :ower 'reaker will feed two downstream destinations.
9. two branch breakers in the same 364 module. These will supply
the 1157 hot water heater and the battery charger
'. 2n7erter transfer switch /integral with in7erter0.
The output of the in7erter transfer switch will feed the lower 115 ?9C
panel module. That module will supply all 1157 loads that are to be
sourced by the in7erter when no shore power is a7ailable.
There is no risk that the in7erter will be o7erloaded by powering the
hot water heater nor can it power the battery charger as both are
wired upstream of the transfer switch.
80 *econd column> 18?1C multi&meter in upper moduleE 187 cigarette&
style outlet- dual&F*' outlet combo in lower module.
30 Third column> 18 ?1C special loads including $always&on( loads
such as the bilge pump. The upper module houses a #eld&installed
'almar *mart Gauge.
3
8
,ote that the :ro,autic: does not reDuire jumpering of unused outputs as the
existing charger does.
3
The *mart Gauge reDuires a H14 duplex wire to the %ouse 'attery 'ank. The leads
must connect directly to the battery terminals not the bus&bars with a 39 fuse in the
positi7e lead. 9 H16 wire runs to the )ngine battery with a 39 fuse terminated
directly to the positi7e battery terminal. 2f the battery terminal has a M"'. holder on
it the *martGauge wire should go on the battery side not the output side.
6-1<-8414 re7 :age 3 of =
40 .ourth Column /far right column0> 18? 1C $normal loads(
consisting of two modules each with four !ush mount breakers
supplying eight loads total.
11& V'C wiring
The shore power receptacle will feed a 349 8&pole breaker in upper&left
module of the 364 :anel. The output of that breaker will supply the
following>
849 %ot Iater %eater breaker
159 'attery Charger breaker
Triplex cable /14-30 to transfer switch input of 2n7erter
The output of the transfer switch will supply the lower&left module of
the panel /7ia return 14-8 cable0. The lower&left module contains the
following breakers>
159 Microwa7e /dri7ing a 644w microwa7e reDuiring max of
1454w0
159 +utlets J con7enience outlets throughout boat
'ecause the hot water heater and battery charger are connected
upstream of the transfer switch they are powered only by shore power
not the in7erter.
The in7erter includes a relay for switching the neutral&ground bonding.
Ihen the transfer switch is supplying the 9C output from shore power
the relay is openE when 9C power is being supplied by the in7erter the
relay is closed so that the neutral is bonded to the ground at the
in7erter.
2n7erter grounding> 2t is important that the in7erter be tied to both the
boatCs 9C and 1C grounds.
The incoming 9C line to the in7erter should include a H14 ground
wire.
The in7erter chassis should also be connected to the 1C engine
ground with a su3cient siKed cable to carry any fault current.
The 9'LC specs dictates that with a 3449 1C supply fuse the
chassis ground will need to be at least H1 9IG wire.
The 9C and 1C ground bus bars must be tied together. 9 H14
wire connecting the two bus bars inside the main panel should
be su3cient.
6-1<-8414 re7 :age 4 of =
(aming con)entions
'us names>
)ngine&'at&'us> Fnswitched )ngine battery power
%ouse&'at&'us> Fnswitched %ouse battery power
)ngine&*witched&'us> *witched )ngine battery power
%ouse&*witched&'us> *witched %ouse battery power
*witches and other de7ices>
)ngine&'attery&*witch> Connects )ngine&'at&'us to )ngine&
*witched&'us
%ouse&'attery&*witch> Connects %ouse&'at&'us to %ouse&
*witched&'us
'us&Tie&*witch> Connects )ngine&*witched&'us to %ouse&
*witched&'us /)mergency use only0
$isc notes*
The ;:G control for the sto7e will be 7ia a .ire'oy *1 controller. The
controller will be connected to the %ouse&*witched&'us 7ia a discrete
fuse /in the house battery box0 rather than a breaker in the 364 :anel.
The 'ilge :ump circuit breaker in the main panel will be fed from the
%ouse&'at&'us rather than the %ouse&*witched&'us so that it is
$always&on.( The wire feeding the breaker in the panel will need to be
fused at the battery end to protect the wire. 2n order to ensure that an
o7erload at the bilge pump trips the breaker in the panel rather than
the upstream fuse the wire from the %ouse&'at&'us to the panel
should be o7ersiKed and fused at a signi#cantly higher rating and
slower trip speed than the breaker in the panel.
The ,a7-Com breaker powers an existing 18&position fuse block located
in a nearby locker.
The '2,,9C;) breaker powers a subpanel /already installed0 in the
cockpit binnacle. That subpanel has breakers for the following circuits
9,C%+"
1)CM&;)?); ,9?
*T"+')
*T)9M2,G
*:")91)"
The anchor windlass has its own discrete breaker at the main battery
box but needs a wire /w- 19 fuse0 to one of the positions on the new
6-1<-8414 re7 :age 5 of =
panel for a labeled ;)1 /next to a blank #ller plate instead of a circuit
breaker0. The existing Iindlass wiring should be inspected for
appropriate wire gauge relati7e to length to minimiKe 7oltage drop and
will be powered from the house bus.
+oals of t#e project include*
Cruise&readiness /su3cient reser7es to sit on hook for se7eral
days0
)lectrical system !exibility /ability to run loads from opposite
battery in emergency using switches pro7ided0
*afety to current 9'LC standards where7er feasible with all
de7iations to be noted to owner /in ad7ance where possible0
.uture&proo#ng
%ighest workmanship standards including>
o %eat&shrink sealed crimp connections made with premium
connectors and proper-calibrated tools.
o Clear labeling of all wires bus&bars fuses breakers
switches etc with permanent labels
o 9deDuate wire gauges for both ampacity and 7oltage drop
o )liminating sources of leakage current by techniDues such
as proper support-attachment of all wires to pre7ent
contact with water wet surfaces or metallic objects and
minimiKing splices or other connections in wires near bilge.
o Co7ered bus bars to facilitate good wire organiKation
o 9ll batteries secured to 9L'C standards /8x weight in each
direction0 and all positi7e battery or un&fused connections
properly insulated.
,ecommended wire si-es and fusing
9ll wiring to be marine&grade stranded 9IG gauge shown rated
145NC.
4
1escriptions of wire gauge reDuirement are of entire pathways
that may include switches etc along the way not just point to point.
Electrician invited to comment and suggest changes. This doc is
suggested design onlyE responsibility for safety is solely electricianCs.
9lternator +utput>H4 min fused at 1449
5
within O( of battery.
6

Ground return for alternator should be H1 min connected to
negati7e bus bar at engine or on *9M) '+;T 9* '9TT)"L
4
'ased ampacity and on 7oltage drop using estimated lengths pro7ided by owner.
5
'lue *ea tech note regarding di@erent siKing guidelines for 9,; fuses speci#cally
discusses fusing H4 wire. http>--www.bluesea.com-resources-=5
6
The alternator end does not need fusing as the alternator cannot output enough
current to o7erload a H4 /or e7en H60 wire.
6-1<-8414 re7 :age 6 of =
G"+F,1 on engine. 9lternately can run H1-4 9IG directly back
to negati7e bus bar for house battery bank.
"egulator> .ield winding and 'A wires to alternator> Fse factory
harness if long enough otherwise replace entire length of both
wires with H14 /fused per 'almar spec0E *ense wire> H14 directly
to %ouse&'at&'us bar /1amp fuse at bus bar0E '& wire run to
alternator negati7e terminal (or directly to House Battery
negative bus bar with #1 wire - TB!)
O
.
)ngine&'attery pathway all the way to *tarter>
<
H1 min 1-4
recommended fused at 8449 type 9,; within O$ of the battery.
=
%ouse&'attery pathway all the way to bus bar on load side of
%ouse&*witch> H8-4 fused at 3449 type 9,; within O$ of the
battery.
%ouse&*witched&'us to Main :anel> H6 min H4 preferred and
likely already in place protected by 64 amp fuse or breaker at
bus bar.
%ouse&'at&'us to the $9lways&on( section of the Main :anel
containing the 'ilge :ump breaker> H14 min H< recommended
34&449 fuse or circuit breaker at bus bar. Fse a slo&blo fuse /or
self&resetting breaker0 to ensure that 149 circuit breaker in panel
/which is slow&trip0 trips #rst if o7erload occurs downstream such
as jammed pump impellor.
)cho&charge unit> H18 min fused at 85 amps at each battery bus
connection
'attery charger> H4 min to keep drop P8Q at 44amps fused at
549. Case ground from charger chassis to 1C grounding bus is
H14 min.
14
,egati7e returns>
O
"unning the MC&614 negati7e lead directly to the %ouse&'at&'us in the battery box
will produce slightly more accurate sensing of the actual battery 7oltage for charging.
May or may not be worth the e@ort. That lead should ha7e less than 4.17 drop all the
way back to the battery if possible as it is part of a measurement circuit. 2f it
connects to the alternator then the O4amps following through the alternator&to&
battery ground at high charge rates can degrade the accuracy. 2f the %ouse&'at&'us
to )ngine ground is 1-4 or larger then e7en at O4amps the drop is below 4.17 and it
should be #ne to simply connect the MC&614 negati7e lead to the alternator
otherwise run a dedicated H18 wire from the regulator negati7e to the %ouse&'at&'us
bus&bar in the battery box.
<
Ihen the term $path( appears it means including all intermediate runs. .or
example the path from the )ngine&'attery to the *tarter includes the wire from the
battery to the bus bar then to the )ngine&'attery&*witch then to the related bus bar
then to the *tarter motor relay and then to the *tarter motor itself.
=
.use type for batteries should be Class 9,; or M"'. for their longer trip delay
times. /Class T also acceptable though siKing di@ers0 This application will use a min
of H1 often larger so a 344 amp fuse is small enough for wire protection yet large
enough to eliminate nuisance trips by either the starter or by the 8kw in7ertor which
can draw 844amps.
6-1<-8414 re7 :age O of =
o :anel to %ouse 'attery box negati7e bus bar /R14C0> H4
o )ngine to )ngine 'attery negati7e bus bar /R3C0> H1
o )ngine to %ouse 'attery negati7e bus bar /R <C0> H1 min.
2n7erter. 8-4 for both positi7e and negati7e. Mfr specCs max wire
length /including wire from battery to bus bar0 of 5C for H8-4
wire. 2f length is longer use larger wire. The %ouse 'attery fusing
appears to be su3cient protection without fusing the in7erter
wire separately. 2n7erter ground should be H1 min.
/uggested components
'attery&fuses> 2f 7ertical space permits 'lue *ea 51=1 or 8151
block
.use panel> 'lue *ea $*afety %ub( series might be a good #t
compactly mounting a combination of a few medium&siKed fuses
and se7eral blade fuses to a single bus.
Bantrex )cho&Charge with remote panel /owner has0
;, =4 amp alternator con#gured for external regulation /owner
has0
'almar *martGauge /owner has0
'almar MC&614 w- alternator and battery temperature sensing.
/owner has0
2n7erter with integral 349 transfer switch. M2*9) *IB."1884 8kw
w- remote operator panel with +,-+.. switch. /owner has0
0t#er notes
;ist below is of wires connected to each bus for bus bar and fuse
mounting planning. 9ny fuses noted are to be within O&inches of bus
bar and are to protect wires not downstream de7ices.
%ouse&'at&'us
o 'attery bank /feeds bus0 J to be fused within O( of battery
bank
o %ouse&'attery&*witch
o 9lternator output J needs fuse at bus bar end
o 'attery Charger J needs fuse
o $9lways&on( 187 line to panel module housing 'ilge :ump
circuit breakerJ needs fuse
o 2nput to )cho&Charge J needs fuse
14
2f the output wire is o7ersiKed the case ground can be one siKe smaller than the
minimum allowed output wire so long as the output wire is fused at no more than
135Q of allowed ampacity of the minimum wire siKe. Iith a 54 amp fuse it is
acceptable to use a H14 as a grounding wire.
6-1<-8414 re7 :age < of =
%ouse&*witched&'us
o %ouse&'attery&*witch /feeds bus0
o 'us&Tie&*witch
o Main :anel J needs fuse
o 2n7erter
o Iindlass breaker
o *to7e ;:G control J needs fuse
)ngine&'at&'us
o 'attery bank /feeds bus0 J to be fused within O( of battery
bank
o )ngine&'attery&*witch
o +utput from )cho&charge J needs fuse
)ngine&*witched&'us
o )ngine&'attery&*witch /feeds bus0
o 'us&Tie&*witch
o )ngine instrument panel J needs fuse
o *tarter relay
6-1<-8414 re7 :age = of =