Saturday, October 17, 2020

Fixing our Electrical System (part iii)

Fixing our Electrical System (part iii)

Time to work on the layout of the AC segment of the Electrical Control Panel.

Two major objectives are 1) Update the wiring so that they have the correct terminations, correct wire size, only one terminal connected to the switched side of the Circuit Breakers. 2) Reduce the risk of short or electrical shocks by covering the AC Circuit Breakers.

The Neutral and Ground AC wires are currently positioned on terminal blocks that will be removed. The new terminal blocks will be on the new Terminal Box Bread Board that will be secured to where the existing terminal blocks are located.

Terminal Block Bread Board

The three horizontal 5 port terminal blocks on the left of the panel are for the 110v AC connections.
The top block will be home for the Neutrals (note the jumper that joins all of the 5 terminals)
The lower block will be home for the Earths (similar jumper joining all of the 5 terminals)

The middle block, lower connections will connect to the Circuit Breakers on the control panel. 
The middle block, upper connections will connect to the appropriate devices (Outlets Port & Stbd, Water Heater, Inverter Charger, and the Air Conditioning System.)  

The three 110v Terminal blocks have insulating covers (the existing blocks do not).


110v AC Terminal Block Schematic

Next I need to make sure I have enough Terminals, Wire, Heat Shrink, Labels etc. to start the project. I'm hoping that it will only take a couple of days to complete - but I'll make sure I have plenty of wiggle room as some of the wires will need to be changed from the blocks to their destination device. I would not be surprised to find that the '110v Outlets' have to be completely rewired and I will be installing GFCI's in each circuit (port and starboard). 

Still hoping we can go sailing before we start this - I say 'we' because it will save a lot of time if we can both get our heads around this project.

So, See you on the Water!

Paul

Friday, October 16, 2020

Fixing our Electrical System (part ii)

 

Fixing our Electrical System (Part ii)

Next step: Prepare the Terminal Block Bread Board.


The Electrical Panel is mounted to a wooden frame that had a hole cut into it that is pretty snug around the switches and circuit breakers in the panel. 

When completed, that panel will have some 'handles' on the front. That will allow the panel to be unscrewed from the supporting woodwork and pulled away to be laid flat with the front now facing down. That will expose all of the switches and breakers while keeping them elevated from the surface of the chart table. Hopefully, that would avoid accidentally operating any of those switches or breakers. The electrical connections from the switches and breakers will be via a loom that's long enough to facilitate pulling the panel away from it's supporting woodwork.

Oh, currently there is a hinge on the bottom edge of the panel, that is supposed to make it easier to get behind the panel, but it doesn't do it very well. Being able to pull the panel away will make it a lot easier to get both to the back of the panel and to all of the terminal blocks that will be mounted on the Terminal Breadboard attached to the hull brackets outboard of the electrical panel.


Cardboard template cutout. I was hoping to be able to make the breadboard 9" tall, but that's not going to fit. So I'll trim it to 7.5" tall.

Next time we're at the boat I'll check to see that it will go in through the gap when the electrical panel is open.







Like many boat owners, I watch a lot of YouTube videos on everything from Cruising stories to Boat repairs, from Rope splicing to Electrical how to's.  Watched one about a new boat on the market, and typically they have nicely done electrical systems. Because of one image, I got the idea of modifying the way that the Electrical Control Panel pulls out.

Right now the big issue is that the panel is only able to hinge out and down by about 50º and that restricts the access both to the wiring on the back of the panel and to the wiring that is on the bulkhead behind the panel.


Right now the big issue is that the panel is only able to hinge out and down by about 50º and that restricts the access both to the wiring on the back of the panel and to the wiring that is on the bulkhead behind the panel.

If I remove the lower hinge, then the entire panel could pull away from the bulkhead. To prevent the switches touching the Nav Table Surface when the panel is laid down, I could attach a few 'handles' that are deeper than the switches. So that's the plan. I would also clean up the edges of the hole in the bulkhead so that there is better clearance between the panel switches and the hole.

Next. Closer review of the wiring.

This photo shows the top most Circuit Breaker which is a double throw for the AC power. It connects the Hot and Neutral lines to the AC Distribution Breakers (A/C, Water Heater, Outlets and Inverter/Charger) 

The switch (back) in the foreground is the Reverse Polarity Test Switch and, just to the right, the Reverse Polarity Indicator Lamp.

If the Shore power Hot and Neutral lines were incorrect, ie. Reversed, then the lamp should light. 
The Test switch is simply to test the lamp.

The problem is that there is that missing connection on the left side of the switch! That switch should connect the lamp to Earth (the neutral and ground are connected on the boat) and the Neutral input at the main AC circuit breaker. If the Lamp illuminates, then that would mean the Neutral side of the breaker is actually a Hot connection! Wrong! Big time!  



Reverse Polarity Switch Circuit

Reverse Polarity Circuit Diagram
This picture shows what I believe is the correct wiring of the Reverse Polarity Indicator system.

Note. It does not show the additional parts of the boat shore power and Inverter power distribution nor does it show the Galvanic Isolator. The sole purpose of the image is to show the wiring of the Reverse Polarity indicator system.

The 'red' wire is not included in the current wiring on the boat (that's the empty tab on the Lamp Test Switch.)


And now the good news! While at the boat yesterday, the template for the Terminal Bread Board fits easily. So I can go ahead and cut the board then attach the Terminal and Fuse Blocks.

New Terminal Block Bread Board

 The New Terminal Block Bread Board is cut to size and the terminal blocks, fuse block and +ve Busbar are all a attached. I used 3/4" #6-32 S/S Dome headed screws and Captive nuts.



I'll drill the holes for the screws that will attach the bread board to the existing wooden fillet that is currently fiberglassed onto the inside of the hull.


Every little step is just that, a step forward. Right now, I'm working on the overall wiring diagram of the bread board. My intent is to get all of the wiring locations figured out before I start ripping into the existing panel wiring. 

This image will auto update if I make any changes.
We're hoping to get out on the water pretty soon, a few days of grumpy weather are already forecast. Looks like sometime next week. 

So, see you on the Water.

Paul

Saturday, October 10, 2020

Keeping track of Boat Work

Service Log

At our sailing club meeting this week (Yes, we are able to have a Socially distanced club meeting outside at a restaurant. ) a sailing friend mentioned how his boat's previous owner kept a log of just about everything he did on the boat. I showed him my online service history log.

Why do I keep it up especially as some of it is repetitive? Simple answer, I cannot remember what I had for breakfast last Sunday, let alone when I last did an oil change on the boat. Of course, it's not just recording the routine stuff like oil changes or filter changes. I try to record just about everything I do that might need to be considered at some future time.

At the top of my Blog Pages is a Tab Menu, it looks like this:-


Click on the 'Service History' tab. It's actually a Google Sheet that is embedded in the page setup, so it's automatically updated when I make a change to the Spreadsheet.
Here's the link:- Service History Link 

Oh, if you would like to receive an email whenever I post a new article in Sailing Eximius, just enter your email address in the 'Follow by Email' field on the side of the blog article pages.  I do not harvest, sell, giveaway or respond to your email, I use Feedburner to automatically send an email once a day if I have posted a new article to this blog. I rarely post more than one article, mostly it's one or two a week.

Comments?

I often get comments from people that I know and occasionally from those that follow my blog. I always respond to those comments, even if it's just a 'Thanks for the Comment' but normally I'll respond considering the comment. Some of those comments have been really useful. It's always nice to hear from readers that have ideas not confined to my little world. So, please, leave a comment if you have one. The comment form is at the bottom of each post. (if there are no prior comments, just click on the 'No Comments' links.

Friday, October 9, 2020

Cabin Upgrades (Part ii)

Upgrading the Cabin Table.

Hit the first snag this morning, having a hard time finding 1/2" Marine Ply. Lowes - none and no idea when it will be available. Home Depot - none. Now looking at specialty stores. I considered using Coosa board but it's over $200 for a single board of 8'x4' so more online searches. 

Found a Dixie Plywood and Lumber Co near Fort Lauderdale. Reached out to them and awaiting a reply - not hopeful as I have tried that with two other companies and no reply after 3 days. We'll see.

Found a vendor in Fort Lauderdale, will contact them in the morning - Saturday.

Weather looks grotty for the next week, if they have the plywood in the morning, I'll check the weather and head down there. But first I'll stop at Lowes to see if they have any suitable ply in stock, it doesn't have to be Marine Grade Ply as it's going to be covered in resin, just has to be decent laminations and glue. If lowes has it, then I'll see if the Fort Lauderdale has anything in stock better, and consider driving down there to check it out.

Have to call the Ford dealer in the morning, I scratched our truck, very gently, but we can see the scratch. Not sure if it's covered by our 'Ding' warrantee.

It wasn't :(

No luck with the Fort Lauderdale vendor. Heading up to Lowes.

Well, Lowes came through! 1/2-4-8 TC BLONDEWOOD PLYWOOD $37.99 and they cut it so that I have two 26.5" x 41" panels, and some left overs that I'm sure will come in handy somewhere/someday.

Of course, I get 5% off that price using my Lowes Card :)











Here's the two pieces I'll use for the Table with the Template sitting in front of them.

The Template was about 1.5" on the narrow side when we test fitted it on the boat, so this shows the correction.

Time to glue and brad the two pieces together. Then I'll cut out the Mast relief.








Both panels sanded (for gluing) and the top panel marked up from the Template.

The mast relief is about 1/4" oversized to allow for the resin thickness. Not sure how  thick it will be around the edges, but 1/4" should be plenty. Ideally the table will not touch the mast.

Charged up my nail gun and loaded with 1" finish nails.

Clamps all ready.

Lunch then let the gluing begin.








Wood glue applied, pretty sure  it would be enough.

Used a spatula to spread it over the whole surface and ensuring that the surface edges were covered.

I have the AC unit running in the garage as it gets pretty hot and humid without it.

Glue takes 24 hours to cure.











Panels attached to each other. Every clamp I own was holding it together.

Then my DeWalt finish nailer easily set 1" brads at 45º from the vertical just to make sure they did not penetrate  the top surface.

Now to wait the 24 hours for it to cure. 

Next step is to clean up all of the edges and cut out the mast relief.

Removed all of the Clamps and turned the top over, minor goof. Even though I used the nailer at 45º, the nails just showed on the top side :(  I didn't check that the nailer power was not on high. No biggy, I just used the wrong end of a nail punch to knock them back down. Sanded up just fine :)

Started sanding the edges flat where the two pieces were about 1/64" different in size. Took about an hour to sand them down.

Next step is to cut out the Mast Relief. Jig Saw and Sander should get that done.

Well, the Admiral (Peggy) had an idea. She asked if I could make the gap between the table and the mast slightly bigger so that it's easy to wipe the table down, including between it and the mast. Good Idea! Consider that done!


TraLa! New Table top woodwork complete.

After cutting the Mast Relief (oversized as requested) all of the edges were chamfered with my router, did have a minor issue.

I have two routers, one I use for hand routing and the other is fitted to a really nice Bosche Router Table, however the Router Table takes a while to setup and I thought this was a job for the hand router. Would have been except that it had broken and I didn't realize it. The clamp that locks the depth of the router bit had cracked. I did a test cut on a scrap of wood and that was fine. As soon as I started the cut on the bottom edge of the table, the router bit depth loosened and instead of a 3/16 cut, it was more like a 1/2" cut! Grrrrr. Fortunately, or because of past experience, I had started the cut on the underside of the tabletop and on the edge opposite from the mast relief. No harm no foul. So I pulled out my router table and we completed the job using that. 
Once the routing was finished, I sanded the edges, filled the divots and any (very few) voids between the plys. Then, once the filler (spackle) was dry, I sanded the whole thing down, looks pretty good.

Next:- Base paint with an Alkid paint, I'll roll on a pale base paint, sand that and apply a second coat before a light sanding.

Selecting the Resin

I have been researching the resin options, methods and suppliers for several weeks. Final choice was to use TotalBoat Tabletop Resin. They have been around a while and are great suppliers of all types of resins. I watch a lot of Boatworks Today videos on YouTube and he promotes TotalBoat products (and several other vendors, but the Resins he promotes are nearly always TotalBoat) .

After watching a lot of videos I figured out the method to use.
  • Prep the table top (the primer should be fine)
  • Setup a workstation with a drip tray to catch the surplus resin run off
  • Make a Tape Dam around the edges of the tabletop
  • Mix batch #1 of resin and makeup 3 cups of colors and 1 of clear resin
  • Apply 1st layer of colors and clear and style (arty bit) the top
  • Remove the tape dam and wet the edges to allow for overflow to carry the art over the edges
  • Eliminate any bubbles with heat gun (my heat gun should do the trick)
  • Allow to dry before adding 2nd or final coat of resin
  • Allow to cure for about 72 hours more is better.
I enquired about issues doing this in South Florida. TotalBoat responded: The resin work time would be reduced to about 10 minutes !!! 

That's Doable, but time really flies when it's fun. We would be better off waiting until the weather cools. The average low temp in South Florida in December is in the low 70s, and that gives more like 30 minutes till the resin 'kicks' and becomes unworkable.

That gives me about 6 weeks of delay time. But will also allow time to get all of the supplies ordered and on site (the workstation is my Garage)

Peggy did have an 'outside of the box' idea - we could rent a refrigerated truck! Or, we could head up the coast, around the Jupiter area where it gets cooler much sooner. Perhaps stay in a motel. The resin  I have chosen is VOC free, so we would just need to be really careful masking off the work area. Great ideas, but I would feel more comfortable working at home.

So, we're delaying work until it gets cooler. Meanwhile I'll order the supplies.

  • 1 Gallon Totalboat Tabletop Resin $65
  • 2 Quart Totalboat Tabletop Resin $50 (because 1 gallon is not enough)
  • Mica Black Diamond Pigment Set $18
  • Disposable Mixing cups $9
Total cost $150, this had better be good!

Stay tuned for progress reports. If you have done anything like this, please leave a comment with any suggestions. 



Wednesday, September 30, 2020

Plan to sleep better with our electrical system

 OR - Fixing our Electrical System

Since we have owned Eximius, we have installed quite a few upgrades and my guess is that we're not the first to upgrade the boat and certainly not the first to make changes to the Electrical System. Every time I open an electrical panel I repeat - I'll have to fix that one day. Well that day is nearly here.

Where we started

We have installed or upgraded the following parts of the Electrical System
And all of that during the past 5 years of ownership. (or should that be 'ownerboat' ?)

During that time the state of the electrical system has improved simply because I have endeavoured to do the right thing and replace any wires where it was necessary and it was in most cases.

Now that we are aware of the kind of issues involved such as:- Incorrect Wire sizes, unnecessary butt joints in the wires, incorrect wire colors, inappropriate wiring terminals and buss bars and missing fuses (by missing I mean there are some systems that should be fused and they are not)

Example of poor wiring (in the bathroomf)
Here's an example.
There are many similar situations on the boat where wires have been joined rather than use a continuous run, the joints are typically twisted, soldered and then wrapped in electrical tape.

Worse are the 110v AC system wires that are joined with Wire nuts used in homes.

There are multiple wires that have nothing connected, just wires dangling.

Tie Wraps are abundant and it's not unusual to have 20 or more tie wraps within a 3 foot loom. That would be ok if they were each functional and neither redundant nor unused.

The Main Electrical Control Panel (Before)

So many things wrong here.
No separation of AC and DC panels.
No protective cover of AC breakers.
Incorrect terminals on lots of wires.
Kinda labeled wires.
Wrong size wires in many cases.





The solution  - at least - my solution.

So far, I have upgraded the wiring that supplies power or data to the device that has been upgraded. But that does not have the kind of impact that I'm looking for in order to sleep well at night.

The big question is, "Where do we start" and I say "we" because this really is a joint effort. Peggy has a pretty enquiring mind and is happy to ask why I'm doing something. Peggy was a Nurse for about 40 years, if you see the amount of technology that Critical Care and Cardiac Care Nurses have to deal with on a daily basis, it's pretty obvious why I explain why I'm doing something or what I intend to do.

If we were to buy another boat, then one thing I would inspect with a much more educated eye would be the Electrical System. Our Boat Surveyor never mentioned it other than noting something that was not working.

Ok, to the task - The Solution.

I posted a question on the C34 Forum and the Association Secretary suggested reviewing the Wiki Links - Wow, there are at least two great examples of what owners have done to solve this issue.

From the Wiki, I learned about a great idea of installing a breadboard at the back of the electrical panel area to mount the Terminal Blocks rather than having them float around behind the panel creating unreachable locations. That will simplify a lot, the board can be made to secure with just a couple of screws then removed, mount the terminal blocks and reinstall it. 

Here's a pic showing the concept.



The General Concept of the Panel Upgrade

The idea is to have enough length of cable looms from the circuit breakers to the terminal blocks that the Breaker panel can be unscrewed from the framework and pulled away to provide access to the wiring terminals as well as make it easy to access the back of the panel.

AC Terminal Blocks (3 - Hots, Neutrals, Grounds)
  • Main AC Power  & Reverse Polarity Switch power
  • Reverse Polarity indicator lamp
  • 110v Outlets Power
  • Inverter/Charger Power
  • Water Heater Power
  • Air Conditioning Power
DC Fuse Block (for normally on services)
  1. Nav table Light
  2. Stereo Memory Power
  3. Weather Clock Power
  4. Dry Bilge Timer
DC +ve Busbar
  1. Power from Battery Selector Switch
  2. Power to DC 1 Circuit Breaker Busbar
  3. Power to DC 2 Circuit Breaker Busbar
  4. Power to DC 3 Circuit Breaker
  5. Power to DC Fuse Block

The existing wires mostly go directly to the Circuit Breakers, some have inline fuses. So there should be plenty of wire to cut off the terminals and then label and connect new terminals with heat shrink tubing to reduce corrosion penetrating into the wires.



Layout of the Terminal Block Bread Board

The -ve, return, busbar is located in the area above the control panel and only requires that the cables are re-terminated, labeled and routed appropriately. I'll still check them to their source device to ensure they are solid, ie. do not include multiple unnecessary but joints and the wires are the correct size and color. If they do not meet those specs they will be replaced.

The spreadsheet below has the terminations for each of the circuits. I'll update it on progress.





Ok, everything has arrived, even the 1/4" 12"x24" White Starboard. I'll measure the space for the breadboard again before cutting. Moving ahead with our Cabin upgrade at the same time, so progress will shift between the two and I'll report as we proceed.

See you on the water.

Saturday, September 26, 2020

Cabin Upgrades

 Time to update the Cabin of our Catalina 34

Our cabin layout is definitely different from every other Catalina 34 (Mk 1 Tall Rig Fin Keel) but it is dark! Not very uplifting.

Step 1 is to replace the cabin table. 
Current Cabin Style
Currently, the Cabin table has 2 fold down leafs and the forward inboard corner is an accident waiting to happen whenever anyone tries to climb up to get in the forward seat.

The bulkhead between the V-berth and the cabin is very dark as are the Cushions.




Mockup of bulkhead, table and cushion

Here's a quick mockup showing a grey background on the bulkhead and a simple blue reshaped table.

Also I've added a cushion to the lower part of the bulkhead.

We're thinking of some artwork or chart covered with a clear resin.




This mockup shows a resin tabletop with artistic beach breaking wave. Definitely adds richness to the cabin.

We'll change out the cushion fabric to a lighter color later on, but it's in the dream bucket.

Considering painting the cabinet fronts and definitely updating the window curtains. Oh, I also need a new bottle of Rum.

Here's the new template for the new table.
The template is 41" for-n-aft and 25" athwartships. 

The cut out for the mast is slightly deeper than the original table which will increase the overall width of the table. 
The length is about 4" shorter than the original which will increase the space available to stepup to the seating.

The template is made from 5/16" plywood.
I scribed the mast cutout onto a piece of paper on the boat and transferred that to the plywood. All straight edges were cut with a circular saw and the cut out as well as the rounded corners were cut with a portable jigsaw.

The actual table will be made from two layers of 5/8" marine ply, all corners cut using a router, both the top and bottom edges will be rounded with the router also. Then the top and edges will be artistically covered using resin. The artwork will either be like the mockup above or pieces of chart, boat pics and C34 logo. We'll see. Now it's down to the boat to see how the template fits.

Stay tuned. 

Paul


Tuesday, September 8, 2020

Labor Day Cruise 2020

 A Great Weekend with the HISC (Hillsboro Inlet Sailing Club)

The initial tally for attendees according to the RSVP's was 4 boats and 14 people, some arriving by car. Not so bad considering we're in the middle of the Pandemic. The final tally was 35 people and 6 boats (one was a dinghy). It looked like everyone brought something to share, the table was quickly covered with everything from chips and dips, tortillas and pulled meat, crackers, cheese, cookies and more cookies. The Ice creams were kept in our freezer until the crowd had made a dent on the table top food supply.

Each club member received a 'thanks for coming' gift: a wine bottle LED lamp kit, they just needed an empty wine bottle to complete the project. Of course there was more Beer than Wine, but after seeing Gettin' Nauti's wine rack, it won't be a problem for everyone.


One of the best parts of these club cruises, is the opportunity to visit the other boats and find out what things that have done to personalize their boat. Rob and Nicole's "Gettin' Nauti" has undergone a lot of projects that make it a one of a kind - I got some great ideas from what they have done.

Rob took the time out to work on his tansom, the newly applied name looks very cool. Suits the crew!




The dockside at the Bahia Mar was alive with club members doing their best to stay socially distant or wearing  a mask. Food, Drinks, Jokes, laughter and even some boat work kept us all engaged for the 3 day weekend.

It took some coaxing to get a few members to accept the mini ice creams, but at least we got a laugh out of them.


Sunday evening, we gathered on the dock astern of Gettin' Nauti for an ad hoc social, it just happened. More stories, more jokes, and more enjoyment of being out and with other club members.

Some people did not get the memo about bringing chairs, but we did ok.


(Notice that Gettin' Nauti's stern is naked in this shot.


A few ventured to the pool, some stayed, it was a bit crowded for others, but at least it was open. 

Monday the 5 boats were still there:- Eximius, Affection, Windpunk, Cookie Monster and Gettin' Nauti. Amanda came by dingy Sunday afternoon. Other's included:- Bob & Pat Schuldenfrei, Ross & Astrid Hunton, Paul & Regina Chasse, Pierre & Ava Holstein, and the Mckisick bunch plus a few more guests.

Cruising points for the club members will be applied for each night they attended. When a club member participates in a club cruising event, they earn a 'cruising point' for their boat, when they have 10 points they earn the year's Cruising Flag.

Member's earn an additional Cruising Point for writing an article for the Inlet Outlet Newsletter and for hosting a cruise.

Member's fly their collection of cruising flags with pride. 


Our next cruise is Octoberfest, that may be a surprise venue.  So stay tuned.

Friday, August 21, 2020

Updating the Solar System Pt 4

 Finishing off the Update

Here's where I am at the moment, the drawing includes the 3rd panel that has not yet arrived.


By chance, we watched a Pacific Yacht Systems video that showed the need for a Fuze between the Charger and the Battery. As mentioned in an earlier post, the boat came with wires from the charger to the battery but are incorrectly 12awg and 14awg but should be 10awg. My plan is to trace the wires from the Charger to their final connection to the battery (might be via a fuse or breaker and, no surprise, they may change cable size and color.) I'll replace them with 10awg Black and 10awg Red cables, while at it, I'll add a breaker between the charger and breaker on the +ve line.

Update Wednesday September 2nd 2020

The panel arrived on Friday, took it down to the boat today and installed it. Went pretty well except that I want to change the way the front edge is attached to the bimini, that'll happen on Thursday. 
But today we saw the benefit of the new panel. The Sun was partially obscured by the trees at the dock, even then we saw the power rise to 60watts compared to just 10watts without the new panel. Probably because the port side (old) panel was almost entirely in the tree shade.

The Victron controller keeps track for the past 30 days, I'll make a habit of sharing the data in a spreadsheet. the spreadsheet below shows each month of data since the install Move to the bottom of the page to see the Month Tabs.

Thursday, August 20, 2020

Updating the Solar System - Part 3

 Putting it all together

We went down to the boat Tuesday with a 'Left to Do' list

Left to do:
  • Install the bimini (repaired and waterproofed.)
  • Measure gap between Aft Shade Panel Zipper ends
  • Secure main solar power cables to Bimini frame.
  • Secure main solar power cables with cable glands
  • Clear out Port Side Locker for access
  • Feed cables from port locker into bathroom and into cabin and secure to loom
  • Restore the Port Side Locker contents
  • Install 30amp circuit breaker/switch to bulkhead adjacent to blue sky controller
  • Remove Blue Sky Controller
  • Install Victron Controller
  • Connect Battery to Victron Controller
  • Connect +ve main solar power cable to 30amp circuit breaker
  • Connect 30amp circuit breaker to Victron controller 'PV +ve'
  • Connect -ve main solar power cable to Victron controller PV-ve
  • Cover port and starboard solar panel to turn off.
  • Make up cables from Port side solar panel to T Branch Connectors (+ve & -ve)
  • Make up cables from Stbd side solar panel to T Branch Connectors (+ve & -ve)
  • Remove covers from solar panels to turn on.
  • Attach Smart Battery Sense unit to Main Battery System
  • Setup Victron Controller using Victron App on cell phone or Tablet
And we got all of that done!
We also had the next two items on the list. But by this time I was sopping wet because of the humidity, it was 100º F on the outside of the boat and even the 80ºF inside, because the AC was running, I was totally washed out. Time to head home.

We quickly ran the Victron Connect app to check the state of solar charging and it was less than 1amp !!!! What the heck . But the heat got me and it was enough for today.

Thursday Aug 20th. Back down to the boat. I started to check things.

  • Was the Circuit breaker ok - Checked - less than 0.01ohms.
  • Check the Voltage from the two panels.
    • Port Panel 19v (the Solar radiation must have been lower then the screenshot was taken.)
    • Stbd Panel 19v
  • Check the Ics at each panel - 0amps!!! or so low it could not read.
  • Check the physical connections inside the Panel Terminal boxes - all secure and correct.
  • Checked the physical connections to the T Branch MC4 connectors - Ah Ha! both pairs had a termination pin/socket not fully inserted - that's why there was 0amps the probes could not reach the pins/sockets.
  • Both pairs of pin & sockets were opened and the inserts fully inserted, they moved in by nearly a quarter of an inch.
With the pin/socket error fixed, the controller showed as per the screenshot on the left.

6.3Amps!! WhooooHoooo!! That's better than we had before from all k3 panels.

We'll check the data again Friday and I hope to see a much better position than over the first two days.

We had no real idea of how the system was performing before this upgrade but the Max Solar charge we have seen for the past few months has been about 1 or 2 amps, and that was with the 3 panels installed.

The new panel from Amazon has not arrived yet, latest shipping info is that it will arrive by 9.9.2020 - Looking forward to see how that improves the system.

 

After this success and as it was not as hot today, I completed two more projects. Finished the install of the new Dry Bilge pump, it works a treat. Then I repaired the Rub Rail on the Port side where it popped out after our rubbing of the dock pylon on our last retur. I'm guessing that the heat softened the soft plastic rail insert and it was under pressure from the nudge on docking.

All the tools cleaned up, boat is ready to take out sailing...

And then along came Tropical Store 3 barrelling up the path from Puerto Rico, expected here Monday. So it's time to secure the boat again. We'll prep the house tomorrow, Friday, and then start on the boat.

Meanwhile I purchased a new pair of Wire Strippers and a new Clamp AVO meter, wish I had them when I started this job, I would have found the issue with the contacts much quicker.

Before I closed up the panel for the new Victron MPPT Controller, I checked the wires from the controller to the batteries. Glum! they are 12AWG and 14AWG. That's bound to cause a voltage loss between the controller and the batteries. I have plenty of 10AWG wire so that will be the next job. 

Oh, and when the new panel arrives:-
  • Attach new panel onto Bimini
  • Monitor Solar Charge Status (to compare with status after connecting new panel)
  • Plug new panel into T Branch connectors (+ve & -ve)
  • Monitor Solar Charge Status
After everything is finished.
  • Put Blue Sky controller on Craigs List
I'll post a followup screenshot of the status tomorrow.

Stay safe out there!

Paul

Saturday, August 15, 2020

Updating the Solar System - Part 2

 Part 2. Replacing the wiring

The existing wiring to the panels is primarily duel cable 10awg wire. The wires are attached to the terminal blocks inside the Panel Terminal boxes using twisted wire inserts. Those connections need to be correctly terminated.

In order to maintain consistent wiring practice between all three panels, the panels will connect to T branch connectors. This means that each panel will have a pair of wires from the terminal box to the T branch connector.
This means that the new panel can be installed at any time and thus allow completion of the system in advance of the arrival of the 3rd panel.

The good news is that the Solar Panel was due between September 13 - 19th, Amazon sent an update today stating that it would arrive between August 13 - 19th. That's next week WooHoo!

The Cable Gland kit from Amazon should have the appropriate size glands to create a waterproof insertion point for the 10AWG cables into the Panel Terminal Boxes.


Just so that it's obvious in 2030 - This is another of the boat projects that is being done during the 2020 Pandemic of Covid19. There's a degree of excitement about the work, it gets us out of the house and should improve the power system on the boat. We're going from 350 watts of solar power that we were told was on the boat when we bought her, to finding that we only had 230 watts of solar panels and then 130 watts after finding that the largest, 100watt, panel is defective. We should end up with 300 watts of solar with a max current of 3.69 amps + 3.59 amps +9.44 amps = 16.82 amps - but it will never get that high. I should be able to get 10 amps when needed.  Of course, the other benefit is that the wiring will be top grade, very reliable and, most importantly as far as satisfaction is concerned, we'll be able to monitor the Solar system which is something we cannot do right now. It's good to know that things are working correctly.


Update Saturday August 15th.

Made good progress today:- After removing the defective panel yesterday, today we worked on the wiring. Once I had detached the cables from the Blue Sky Solar Controller and traced them up into the aft end of the Nav Area covered shelving, Peggy started snipping the tiwraps that held the cables to the loom in the bathroom. Meanwhile, I removed the wires from the remaining two panels and extracted the main wire from the Panel mounting down to the Port Side Combing where it passes into the area inside of the Port Side Cockpit Locker

Once inside the locker, I was able to see where the cable came into it. There has to be a hundred tiwraps holding the loom together and to the large Exhaust pipe that reaches up to the top of the locker.










Just as we have found virtually everywhere in the boat electrical system, the Solar Panel Power wire has multiple connections, one was a 4 screw chocolate block and another was the dreaded twist, solder and cover with sticky electrical tape.

The new wire from the panels will be two pieces of continuous 10AWG wire.

While in the locker I was able to see the original Catalina Wiring for the Stern light glassed into the underside of the Combing area. 

As we make further improvements to the boat, I'm sure we'll fix the rest of the wiring in that area, I cannot think what it must all be for? I replaced the Engine Harness wiring a couple of years ago, so I know that's good.





With a heavy rain cloud in sight heading our way, we quickly stowed the locker contents and closed up the boat. By that time we had the cable double cable entry gland installed and the cables from the solar panels lead all the way into the Port side Locker. Monday we should be able to complete the wiring of the panels and the installation of the new Victron MPPT Solar controller.

When we got home, there was a pile of stuff from Amazon waiting on our doorstep. The Controller, Battery Smart Sense unit, 30 amp circuit breaker/switch, and the box of cable glands.
The only thing left to arrive is the new 170 Watt panel.

Part 3 should conclude this project. We're planning on a sailing trip next weekend the 22nd of August, so no pressure !!!

See you on the water.

Paul


Monday, August 10, 2020

Updating the Solar System

The Solar Problem


When we purchased Eximius, we were told that the Solar Panels were a total of 350Watts with 2 x 100 Watt panels and 1 x 150 Watt panel. The solar charge has never lived up to expectation, and I wondered why!


My first thought was that the supply wires from the panels to the solar charger were undersized and that we were experiencing voltage loss over the length of the wires.

The wires are twin 10AWG and length is approximately 24’ one way, or 48’ round trip.


Looking up in the electrical tables for the voltage loss over that length of 10AWG cable I found that the resistance of that wire is 48’ x .102Ω/100feet = 0.049Ω≈ .05Ω


With the panels connected in Parallel, the max current would be about 15amps

Voltage Drop, Vd, = I x R = 15amps * .05Ω = 0.75v


That's not a huge voltage drop but more than I would expect.

The Solar Panels are mounted on top of our Bimini so we cannot see the underside of them, and we didn’t think to take pics when we had the Bimini off a year ago for restitching. I took photos this week.

The panels are not 350Watts!!!!


We have 2 x BP365U solar panels which are each 65watt panels and 1 x ICP SolarTech 100w panel.

So total wattage would be 230Watts and that was when new, which seems to have been in 2003. They have a 25 year warranty of 80% nominal output. So realistically, we have somewhere between 180watts and 230watts.


So taking a mid point on the 17 year old panels, let’s say we have 200 watts. The panels in parallel should have a voltage of 21v and max current of 14amps. So my calculations above would seem valid.


We have a Blue Sky 251 2i Solar Boost MPPT Controller. Which has a 25v, 25amp capability. Which would seem very capable of handling the output of the panels and the battery charging.


Oh, the Batteries: We have 4 6volt Trogan 105 Batteries connected in series and parallel to provide a total of 12v and 450 Ah at the 20 hour discharge rate.


Upon inspection, we found that the Wire from the solar panels is showing signs of damage and the connections that join the panels in parallel are not up to my spec (they seem to be covered in electrical tape and liquid tape, yuk) also the wire passses through the top of the port side combing through a drilled hole which has been covered with a huge goop of silicone sealant. 


The MPPT controller does not have any management utility, there is an upgraded version that does, but it would be cheaper to replace the unit.


I have decided to replace the wiring, I’ll use individual 10AWG wires and MC4 connectors along with a suitable cable gland where the power line passes through the fiberglass of the boat. I’ll also change the MPPT controller for one that has a remote management facility (most likely bluetooth) in order to correctly tune the charger to the system, which will include a temperature sensor on the battery bank.


Now to decide on the controller and the wiring cables, connectors and the cable clam to provide a waterproof pass throug
  • 30' of 10 AWG Black Multistrand Tinned Copper Wire
  • 30' of 10 AWG Red Multistrand Tinned Copper Wire
  • 6 MC4 Connectors Male/Female Pairs
  • 1 of 1M-3F Branch Connector 
  • 1 of 1F-3M Branch Connector 
  • Twin Cable Clam
  • Victron SmartSolar MPPT 75/15 Solar Charge Controller 75V 15A with Bluetooth

 Found all of those on Amazon. I don't have a crimp tool for the MC4 connectors, hence choosing a kit that includes the crimper and wrenches. Here's a link to the shared ideas list on Amazon 
  - 

We went down to the boat today to further inspect the wiring. The Wire, Terminals and Crimp kit as well as the twin cable clam had all arrived, time to get dirty.

Step one was to remove the Bimini canvas so that we could get to the underside of the panels. The two 65w panels have terminal boxes affixed to their undersides, with the covers off I could see the connections and the diodes, that's a good start, but the larger panel wire is connected to the Stbd side aft panel (65w) via a hole in the terminal box and a large goop of silicone. Grrrr.

So, we tested the panels.

  • Port Side 65w BP Solar panel - 17.9 volts 3amps
  • Stbd Side 65w BP Solar panel - 17.9 volts 3amps

  • Foward 100w Solar Panel - 0.00volts 0.0amps
    • Inspecting the panel, it has no terminal block and I cannot see where any diodes could be fitted! The wiring looks awful and it's connected from the Port Aft corner of the panel to the terminal box  on the Stbd panel. I checked at the inter panel connections that are on this panel and they were all zeros! This panel it no use!


My conclusion is that the 100w panel is beyond my repair and is probably 13 years old.

Time to look for a new panel. I searched for a panel that was the same physical size 60in x 29in and could not find one, but I did find a 170w panel that uses Z brackets and they would extend the size of the panel by about 1.5" with luck it will fit, if not I'll just have to add a wider brace between the two aft panels and the new forward panel.

Here's the updated materials list

  • 30' of 10 AWG Black Multistrand Tinned Copper Wire
  • 30' of 10 AWG Red Multistrand Tinned Copper Wire ✔
  • 6 MC4 Connectors Male/Female Pairs ✔
  • 1 of 1M-3F Branch Connector ✔
  • 1 of 1F-3M Branch Connector ✔
  • Twin Cable Clam✔
  • Victron SmartSolar MPPT 100/20 Solar Charge Controller 100V 20A with Bluetooth 
  • Victron Smart Battery Sense Long Range (Up to 10M)
  • BougeRV 170 watts Monocrystaline Solar Panel 12volts
  • BougeRV Solar Panel Mounting Z Brackets✔

Everything has either arrived or is ordered, the last item to arrive is, according to the amazon schedule, the solar panel due on September 3rd. Meanwhile I can get the other wiring taken care of. 







 

 So there's a few items to arrive, I hope to get as much as I can done before the new pan el arrives in September. I'll take more pics and post another article then. Maybe I can get Peggy to take a video showing what we are doing.


Stay tuned. 

Tuesday, July 21, 2020

Just a bit of Boat Work

New Anchor

Our primary anchor has been a Delta 25lb plough style anchor. It gets great reviews, but we have dragged often even with 90' of anchor rode out in 7' of water, with a 4' anchor roller to water length that's 11' and 7:1 rode would be 77', yet we would still drag even after digging the anchor in by backing down.

West Marine had a new model of anchor that had a list price of $299 on sale for $68, at that price it was worth trying.  

To install the anchor, I first had to remove the existing anchor, the shackle was seized but soaking in WD40 for 24 hours. With the new anchor attached, I next needed to remove our secondary anchor which is past it's best by date by a few years. In order to remove it, I had to pull out all of the rode for both anchors. That's 100' of chain on the primary anchor and a further 250' of 7/8" 3 strand rope. Then the 50 of chain and 150' of 7/8l" rope on the old secondary anchor. 

With all of the rode out of the anchor locker, I was able to give it a significant clean, it's been a couple of years.

There was a plastic cover for an old hole near the top of the locker, I peeled that off and cleaned up the area then looked for a suitable cover.

I found a 'Sample' of formica available at Lowe's for $0.25 including shipping !!! 

I'm guessing that the hole (behind the white piece of formica) was probably the original position of the 12v power outlet which had been moved forwards so that it was out of the way of the flukes of the anchor.

To secure the panel in place, I used double sided duct tape, it stuck really well. The Delta anchor (shown in the lower left corner of the photo at left) does not have flukes that are likely to damage the sides of the anchor locker.

Then the rode for both anchors was put back in place, pretty neatly, by using a boat hook to push down the anchor line into the depths of the locker. 
That mesh bag seen in the right lower corner of that photo is the bag that contains our Snubber. Also in the locker is our Day Marker for when we use the anchor during the day.


Another job was to complete the new backing plate for the shower thermostat.  When I installed the thermostat, I didn't realize that the front of the control could be removed, so the hole drilled in the surface in which it was mounted was cut to allow the control handle to pass through. 
The thermostat is held in place by two pipe supports on the inside using 4 bolts. I replaced those today with countersunk bolts and then covered the hole with another piece of the Formica sample from Lowe's. Again, secured in place by using double sided duct tape.

The result is actually better then expected. The panel fits really well behind the thermostat control knob.







With this panel complete it looks much more 'finished'

The top edge of the panel slides up behind the underside of the teak countertop surround.


Last project for the day was to modify the way that the new fan in the v-berth was installed.

When the fan was attached to the teak on the port side of the v-berth, it was too close to the deck head. Consequently the fan could strike the deck head :( 

Today I removed the fan, screwed an extension  piece of teak about 7" tall to the teak rail and then the fan to the teak extension. The whole job took about 15 minutes, but that included getting the tools ready and the clean up afterwards. 

So today was a nice and quick visit with three projects crossed off the list.

We're hoping to be able to take the boat out on a cruise down to Biscayne Bay starting this weekend, but the weather is not cooperating, We're happy to let it slide for as long as necessary, but if we don't get away by Wednesday we'll take a break and spend a night at a hotel to celebrate. 

Hope to see you on the water.

Paul & Peggy

Thursday, June 25, 2020

Leak from Engine's Raw Water Filter

Leak from Engine's Raw Water Filter


During our Father's Day Weekend Cruisette, when we arrived at the Bahia Mar, we realized that the Bilge Pump had run twice and the Bilge had a couple of inches of water.

Peggy is always good at finding leaks, so while I was out chatting to boat buddies, Peggy was hunting down the leak. Turned out it was from the Engine's Raw Water Filter.

When I looked at it, water could be seen dripping out of the clear plastic cup that holds the filter.

I checked it was screwed onto the housing securely, it was, so I closed the Raw Water Thru hull and unscrewed the filter cup.

The cup has a seal and that seal appeared to have a split in it's surface. Upon removing the seal, I noticed that it was way to big for it's location, probably swollen for some reason. It was certainly not going to go back in place without a struggle which would probably worsen the split.

I had installed that new filter in 2018, and had also replaced the AC Raw Water Strainer with the same type of filter, figuring out that if ever the Engine Raw Water filter had an issue, I had a spare that I could steal from the AC unit.

I considered using the AC Raw Water strainer cup and seal to get us back home. After an extensive online search, I could not find a replacement seal, so I ordered two new Filter assemblies, one to fix the current issue and a spare. As the old filter cup was going to be replaced, I decided to replace the Seal with a ring of Silicone Sealant. After cleaning the Filter Cup and making sure it was totally dry, I applied a healthy coat of sealant in the grove where the seal should be. Then I let it cure for 24 hours.
Sunday afternoon an inspection of the silicone showed it was fully cured. I installed, the now repaired, filter cup and we did a test run of the engine. No leaks. WooHoo!

When we got home on Monday, the new filters were waiting on my doorstep.

Life is good.

See you on the water.