Task: Refurbish breaker panel

Status: 3/23/2012

The various breaker panels near the galley sink are designated:

• Panel 1: lower, next to the volt meter.
• Panel 2: upper, outboard to starboard
• Panel 3: upper, inboard of Panel 2
• Panel AC: lower, inboard of Panel 1 (all 120v AC breakers)
• Panel 4: very top

The breaker panel at the nav station is designated:

• Panel N

Many of the screws, terminals, and buss bars on these breakers are extremely corroded and some of the breakers will need to be replaced. Note that the breakers on Panel 4 are of a different make and look to be in good shape.

All the breakers have been removed from panels 1, 2, 3, and AC. The breakers are made by Wood Electric Co. Inc. and are part number 112-2NN-101, where NN is the number of amps for which the breaker is rated (for example, a 15-amp breaker is part 112-215-101). Wood Electric no longer exists, but a direct replacement part is manufactured by Potter & Brumfield (Tyco Electronics). The part number is W31-X2M1G-N, where N is again the breaker amperage rating. These can be found at Allied Electronics and other electrical distributors.

The existing breakers will be cleaned and tested. Ones that do not work will be replaced.

A wiring diagram has been started: File:X-dimension breakers.pdf

Status 4/4/2012

All of the breakers from panels 1, 2, 3, and the AC panel have had their contacts cleaned and have been tested under load.

Breakers that are marked good were able to handle about 100% of their rated amperage for over a minute without getting warm, and when increased to 150% - 200% of their rating, tripped in less than 30 seconds. This corresponds to the breakers' specification.

Of the breakers mareked BAD, some of them didn't work at all (open). Some of them became very hot under load. Some of them had intermittent connectivity (these all got hot as well), and one of them actually started to smoke.

Panel	A	Name	Status
1-1	30	Cabin Lites	Good
1-2	30	Cabin Lites (red)	Good
1-3	5	Spreader Lts	Good
1-4	15	Mast Head	Good
1-5	10	Bow	Good
1-6	15	Nav Lite Main	BAD
1-7	10	Auto Pilot	Good
2-1	15	Nav Lite Aux	Good
2-2	10	Compass	Good
2-3	15	F.W. Pump	Good
2-4	15	Salt	Good
2-5	15	N/G	Good
2-6	30	Nav. Inst.	BAD (hot, trips @ 25A)
3-1	30	Radio Phone	BAD (intermittent)
3-2	5	Stove	Good
3-3	30	F. Pump	BAD (smokes!)
3-4	15	Footlites	Good
3-5	15	(blank)	BAD (open)
3-6	15	Bilge Blow	BAD (hot)
4-1	5	Spare	?
4-2	10	Bilge	?
4-3	15	Fridge	?
AC-1	30	AC Main	BAD (case damaged)
AC-2	15	Spare	BAD (open)
AC-3	15	Hot Water	BAD (open)
AC-4	15	Outlets 120v	BAD (open)
AC-5	15	Battery Charger	BAD (open)
AC-6	15	Spare	Good

Status 4/20/2012

Breakers from Nav Station (Panel N) have been removed and cleaned, but not yet tested. Several of these breakers were physically damaged during the removal process due to severe corrosion.

Panel	A	Name	Status
N-1	30	FM Radio Phone	? (untested)
N-2	5	Free	BAD (damaged)
N-3	15	GPS	? (untested)
N-4	15	Free	? (untested)
N-5	15	NavMan	BAD (damaged)
N-6	15	Sta Light	BAD (damaged)

12-volt Circuits

Here is a list of the 12-volt circuits on the boat. Where appropriate new names have been suggested. The Orig. Breaker column includes the breaker rating and the panel number and location of the original breakers.

Circuit Name	Orig. Name	Orig. Breaker	True Amps
Cabin Lights	Cabin Lights	30A 1-1	19.1
Foredeck Light	Spreader Lts	5A 1-3	1.7A (20W bulb)
Tri-Color	Mast Head	15A 1-4	2A (25W bulb)
Steaming Light	Bow	10A 1-5	0.4A (5W bulb)
Nav Lights	Nav Lite Main	15A 1-6	3A (3 x 12W bulbs)
Auto Pilot	Auto Pilot	10A 1-7	?
Nav Lights Aux [2]	Nav Lite Aux	15A 2-1	?
Compass [3]	Compass	10A 2-2	?
Fresh Water Pump	F.W. Pump	15A 2-3	10A
Nav. Inst.	Nav. Inst.	30A 2-6	?
Propane	Stove	5A 3-2	?
Fuel Pump [6]	F. Pump	30A 3-3	10A (5A measured)
Footlights [7]	Footlights	15A 3-4	?
Bilge Blower	Bilge Blow	15A 3-6	?
VHF Radio	FM Radio Phone	30A N-1	4.9A (6A fuse recommended)
GPS	GPS	15A N-3	?
NavMan	NavMan	15A N-5	?
Sta Light	Sta Light	15A N-6
Anchor Light [8]	n/a	n/a	0.8A (10W bulb)
Horn [9]	n/a	n/a	3A
FM Radio [10]	n/a	n/a/	5A (5A fuse recommended)

Notes:

• 1. Do we need a separate breaker for red lights? probably not, since many of the red lights are on the "white" circuit.
• 2. Do we need auxilary nav lights? If they work, perhaps we'll keep them.
• 3. Compass light circuit might be combined with lights for instrument panel
• 4. Do we have a salt water pump? Do we need one?
• 5. The Nav station subpanel circuits might be moved to the main breaker panels.
• 6. Fuel pump breaker will be one of the "always on" breakers on panel 4.
• 7. Do we need a separate breaker for footlights? Perhaps they should be combined with cabin lights and have dedicated switch.
• 8. Anchor light could not be turned on with original wiring
• 9. Electric horn not originally installed on boat. Perhaps this could be combined with another circuit, such as Nav Inst.
• 10. FM Radio is currently on the white cabin lights breaker.

Lights Sub Panel:

• Nav Lights 3A (3 x 1A [1004 bulbs])
• Steaming 0.4A
• Tricolor 2A (25W bulb)
• Anchor Light 1A (10W bulb)
• Foredeck 1.7A
• Instrument Lights 1A (tach: 0.27A [194 bulb]; temp: 0.12A [53 bulb]; oil: 0.12A; compass: 0.04A [LEDs])

Total lights draw: < 10A

Cabin Lights

Types of Cabin Lights

• Red/White circular ceiling lamps. These have a SPDT switch (ON-OFF-ON) to switch between white and red mode. In white mode, two 6W festoon lamps are lit. In red mode, one 6W red festoon lamp is lit. Max current: 1A.

• Black swivel lamp. These have one 5W bulb each. Current: 0.5A

• Square panel lamp. These are 6" x 6" square panels and use an automotive type 1141 bulb. Current 1.6A

• Gold reading lamp. These use a 10W bi-pin bulb. Current: 0.9A

• Red/White flourescent lamp. Uses SPDT switch (ON-OFF-ON) to turn on one 8W flourescent bulb at a time. Maximum current: 0.7A

• Circular LED ceiling lamps. These have an array of white LEDs. Amperage is yet to be determined, but is probably less than 0.1A.

• Circular white ceiling lamp. This lamp above the sink has the same housing as the LED lamps, but it contains two 10W bi-pin bulbs. The SPDT switch (ON-OFF-ON) can turn on either one or both bulbs. Perhaps this lamp should be rewired for red operation.

List of Cabin Light Fixtures

• Forward Cabin: two square panel lamps facing forward on forward side of bulkhead (2 x 1.6A)

• Forward Cabin: two gold reading lamps at aft end of cabin above berths (2 x 0.9A)

• Head: R/W circular (1)

• Forward locker, starboard side: square panel lamp (1.6A)

• Next locker, starboard side: square panel lamp (1.6A)

• Main cabin: 4 R/W circular lamps (4 x 1A)

• Main cabin: 2 LED lamps (2 x 0.1A)

• Main cabin, above sink: 1 circular white lamp (1 x 2A)

• Main cabin: 6 black swivel lamps (6 x 0.5A)

• Main cabin: flourescent lamp over stove (0.7A)

Summary

The total amperage of the above light fixtures is 19.1A. As of 4/4/2012, it still needs to be determined which lights are on the white circuit and which are on the red circuit. All the lights should also be tested with a 12 volt battery to determine if all the circuits actually work. The footlights also need to be examined to determine if the circuits work and how much current they draw.