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Maxum Owners Forum
On the subject of Grey Market boats

Gray Market boats are boats built outside of the US for sale abroad. They can be purchased abroad and brought into this country legally, these boats need not comply with ABYC standards or US Coast Guard standards, except in displaying a HIN (Hull Identification Number) sanitation device and navigation lights. You should be aware that some dealers bring these boat into the US for sale, some owners have imported them themselves from the Caribbean charter trade. If you're interested in a Foreign built boat, call the manufacturer and check if the HIN# was built of the US market. Most insurance companies will not insure a Gray Market boat in the US. Just FYI. Jc

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Maxum Owners Forum
Green grounding wires:

Dear Jim,

A haunting question that I have not heard addressed deals with the grounding system that is used in our boats. So many of the solderless connectors that are used are open ended, thereby allowing moisture and corrosion to take place.  Upon careful examination, most of the green grounding wires on my boat already are showing signs of oxidation.

Question #1:  Does this corrosion impede the effectiveness of the grounding system?
Yes,

Question #2:  Should any tests be performed between the parts that are being protected to see if there is a high resistance?
Yes, Resistance between the part connected and the wire should not be over one ohm. It actually should be in the microhm region. But most measuring equipment you have won't measure readings that small. Corrosion block, new connectors, and new wire are all in order here. There are some new connectors with non corrosive gels inside the connection as well as heat shrink ends that might do well in these conditions. See the "Ancor" website for their new products. http://www.ancorproducts.com/

Question #3:  Is the industry standard open for such connectors and grounding?
I am sure there must be, but I do not know it offhand.
Research follows:

ABYC section E9.17.12 deals with wiring connections and details that connections be made to withstand tensel force testing, (pull apart) but does not detail resistance testing.
Section E-2 deals with Cathodic Protection but does not cover wiring.
From ABYC Section E4 Lightning Protection, requirements for installation:
E4.7.2 Conductive Joints, (for lightning protection) conductive joints shall be made and supported in accordance with ABYC E9, DC electrical systems under 50 volts, and E4.7.2.1, shall have an electrical resistance not in excess of that of two feet (0.6m) of the smaller diameter conductor.

Question #4:  What is the purpose for the grounding (all through hull fittings)?
1.- To bring the metal to a common electrical potential, for safety reasons.
2.- Lightning protection.
3.- To reduce the effects of galvanic corrosion by tying the underwater through hulls and under water metal to the boats sacrificial zinc system.

In addition, since the green bonding system uses #6 and #8 wire. You will need a crimper large enough to remake the connections. You won't find these in your typical marine store, although I feel personally feel you should be able to, after all they sell the lugs. You can use a Greenlee K2-1BGL or a Thomas and Betts ERG2007. If you've got more time than money you can check E-bay and pick one up for 1/2 price. Replace your corroded wire far enough back to get a good connection, corrosion block and then shrink wrap the splice. While you are looking at your bonding system check to insure that your rudder post is grounded, many of our boats were not. In your work, use ring terminals or captive spade terminals, and use ONLY marine grade green or green with yellow strip wire.
E8.15.19 Solder alone cannot be used as a connection on a boat, a mechanical connection, (crimp) must be used.
E8.15.11 Conductors must be supported every 18".

I await your response. Thanks for your help.    
Ron Radford  Cem1inc@aol.com

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Maxum Owners Forum
Electrical Do's and Don'ts:

The following is not intended to make you fully versed with how to wire a boat. It is intended to let you know where to find some of the standards to which most boats are built. Further it will hopefully improve the way some of us wire our boats and point out why, in some cares it is done one way rather than another. The following text contain excepts from the 61 page section of the two inch thick ABYC standards manual.

Technical Data

Excerpts from ABYC Section E-11

AC and DC Electrical Systems on Boats

American Boat & Yacht Council Standards for Boats 7/2003

Based on ABYC's assessment of existing technology, and the problems associated with achieving the goals of this standard, ABYC recommends compliance with this standard (E-11) for all systems and associated equipment manufactured and/or installed after July 31 2004.

Conductors shall be at least 16 AWG (except 18 AWG may be used as internal wiring in panelboards, and on other specific exceptions). E11.16.1.1.2

(for DC systems) Conductors and flexible cords shall have a minimum rating of 50 volts. E11.16.1.2.1

(for AC systems) Conductors shall have a minimum rating of 600 volts. E11.16.1.3.1

(for AC systems) Flexible cords shall have a minimum rating of 300 volts. E11.16.1.3.1

Where AC and DC conductors are run together the AC conductors shall be sheathed, bundled, or otherwise kept separate from the DC conductors. E11.16.4.1.5

(for AC systems) In engine spaces, the temperature rating shall be at least 75°C dry, the insulation shall be oil resistant. E11.1.3.4

Wiring connections shall be designed and installed to make mechanical and electrical joints without damage to the conductors. E11.16.3.1

Ring and captive-spade type terminal connectors should be the same nominal size as the stud. E11.16.4.1.12

Twist-on connectors (wire nuts) shall not be used. E11.16.3.6

Metals used for the terminal studs should be corrosion resistant and galvanically compatible with the conductor and terminal lug. Aluminum and unplated shall not be used for studs, nuts and washers. E11.16.3.3

Solder shall not be the sole means of the mechanical connection in any circuit. (Exceptions are allowed in the standard.) E11.16.3.7

Current carrying conductors shall be routed as high as practicable above the bilge water level and other area where water may accumulate. If conductors must be routed in the bilge or other areas where water may accumulate, the wiring and connections shall be watertight. E11.164.1.7

No more than four conductors shall be secured to any one terminal stud. If additional connections are necessary, two or more terminal studs shall be connected together by means of jumpers or copper straps. E11.16.4.1.11

AL conductors shall be supported and/or clamped to relieve strain on connections. E11.16.4.1.4

Solderless crimp-on connectors shall be attached with the type of crimping tools designed for the connector used and which will produce a connection meeting the requirements of ABYC E11.16.3.3. E11.16.3.8

Marine Wiring Color Code For DC Systems:
As approved by ABYC in E-11 - Table XIV - 7/2003

Color	Use
Green, or Green w/yellow stripe(s)	DC Grounding conductor
Black or Yellow	DC Negative Conducors
Red	DC Positive Conductors

Marine Wiring Color Code For AC Systems:
As approved by ABYC in E-11.16.2.2.1 7/2003

Color	Use
Black or Broun	Ungrounded Conductor
White, or Light Blue	Grounded Neutral Conductor
Green, Green W/Yellow Stripe	Grounding Conductor
Red, Orange, Blue	Additional Ungrounded Conductors
Black w/Red Stripe	Additional Colors for Ungrounded Conductors (Black)
Black w/Blue Stripe
Black w/Orange Stripe

Marine Engine and Accessory Color Code:
As approved by ABYC in E-11 - Table XV - 7/2003

Color	Item	Use
Light Blue (Lt Bl)	Oil Pressure	Oil Pressure Sender to Gauge
Dark Blue	Cabin & Instrument	Fuse or Switch to Lights
Brown (Br)	Generator Armature	Generator Armature to Regulator
	Alternator Charge Light	Generator Terminal or Alternator
		Auxiliary Terminal to Regulator
	Pumps	Fuse or Switch to Pump
Green/Stripe (G/x) (Except G/Y)	Tilt down or Trim in	Tilt and or Trim Circuits
Dark Grey (Gy)	Navigation Lights	Fuse or Switch to Lights
	Tachometer	Tachometer Sender to Gauge
Orange (O)	Accessory Feed	Ammeter to Alternator or
		Generator Output and
		Accessory Fuses or Switches
	Common Feed	Distribution Panel to Accessory Switch
Pink (Pk)	Fuel Gauge	Fuel Gauge Sender to Gauge
Purple (Pu)	Ignition	Ignition Switch to Coil & Electrical Instruments
	Instrument Feed	Distribution Panel Electrical Instruments
Tan	Water Temperature	Water Temperature Sender to Gauge
Blue/Stripe (BL/x)	Tilt up or Trim out	Tilt and/or Trim Circuits
Brown w/ Yellow Stripe (BY) or Yellow - see note	Bilge Blowers	Fuse or Switch to Blower
Yellow w/ Red Stripe (YR)	Starting Circuit	Starting Switch to Solenoid

Note: If yellow is used for DC negative, blower must be brown with yellow stripe (BY)

Wire conductor size must be chosen with the use of the devise in mind and well as the run length and the routing of the wiring. Conductors used for electronic equipment, navigation lights or other circuits where voltage drop should be kept to a minimum shall be sized for a voltage drop not to exceed 3%. Conductors used for lighting (other than navigation lights) and other circuits where voltage drop in not critical may be sized for a voltage drop no to exceed 10% . Wiring that travels through the engine compartment must be further de-rated. Proper tables are in the ABYC manual and not inclued as part of this text.

The ABYC can be contacted at:
American Boat and Yacht Council, 3069 Solomans Island Rd, Edgewater, MD 21037.
And on the internet at http://www.abyc.org

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Maxum Owners Forum
Master Mariners: