Re: Crimp, Solder, Shrink Tube????
Here are some of the important ABYC Standards for Marine DC Voltage Wiring.<br /><br />E-9.17 INSTALLATION<br />E-9.17.1 Wiring shall be installed in a manner that will avoid magnetic loops in the area of the compass and magnetically sensitive devices. Direct current wires that may create magnetic fields in this area shall run in twisted pairs.<br />E-9.17.2 Junction boxes, cabinets, and other enclosures in which electrical connections are made, shall be weatherproof or installed in a protected location to minimize the entrance or accumulation of moisture or water within the boxes, cabinets, or enclosures. <br />E-9.17.3 In wet locations, metallic junction boxes, cabinets, or enclosures shall be mounted to minimize the entrapment of moisture between the box, cabinet, or enclosure and the adjacent structure. If air spacing is used to accomplish this, the minimum spacing shall be 1/4 inch (7mm).<br />E-9.17.4 Current carrying conductors shall be routed as high as practicable above the bilge water level and other areas 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.<br />E-9.17.5 Conductors shall be routed as far away as practicable from exhaust pipes and other heat sources. Unless an equivalent thermal barrier is provided, a clearance of at least 2 inches (51mm) between conductors and water cooled exhaust components, and a clearance of at least 9 inches (230mm) between conductors and dry exhaust components, shall be maintained. Conductors shall not be routed directly above a dry exhaust.<br />EXCEPTIONS: 1. Wiring on engines.<br />2. Exhaust temperature sensor wiring.<br />E-9.17.6 Battery cables without overcurrent protection shall comply with the following:<br />E-9.17.6.1 Battery cables shall be routed above normal bilge water levels throughout their length;<br />E-9.17.6.2 Battery cables shall be routed to avoid contact with metallic fuel system components;<br />E-9.17.6.3 The ungrounded battery cable shall be routed to avoid contact with any part of the engine or drive train.<br />E-9.17.7 Conductors that may be exposed to physical damage shall be protected by self-draining loom, conduit, tape, raceways, or other equivalent protection. Conductors passing through bulkheads or structural members shall be protected to minimize insulation damage such as chafing. Conductors shall also be routed clear of sources of chafing such as steering cable and linkages, engine shafts, and throttle connections.<br />E-9.17.8 DC conductors shall be sheathed, bundled, or otherwise kept separate from AC conductors.<br />E-9.17.9 Conductors shall be at least 16 AWG.<br />EXCEPTIONS: 1. 18 AWG conductors may be used if included with other conductors in a sheath, and do not extend more than 30 inches (760mm) outside the sheath.<br />2. Conductors having a current flow of less than one amp in communication systems, electronic navigation equipment and electronic circuits.<br />3. Conductors that are totally inside an equipment housing.<br />E-9.17.10 Conductors shall be supported throughout their length or shall be secured at least every 18 inches (455mm) by one of the following methods:<br />E-9.17.10.1 By means of non-metallic clamps sized to hold the conductors firmly in place. Non-metallic straps or clamps shall not be used over engine(s), moving shafts, other machinery or passageways, if failure would result in a hazardous condition. The material shall be resistant to oil, gasoline, and water and shall not break or crack within a temperature range of -34°C (-30°F) to 121°C (250°F);<br />E-9.17.10.2 By means of metal straps or clamps with smooth, rounded edges to hold the conductors firmly in place without damage to the conductors or insulation. That section of the conductor or cable directly under the strap or clamp shall be protected by means of loom, tape or other suitable wrapping to prevent injury to the conductor;<br />E-9.17.10.3 By means of metal clamps lined with an insulating material resistant to the effects of oil, gasoline, and water.<br />EXCEPTIONS: Exception to E-9.17.10:<br />1. Battery cables within 36 inches (910mm) of a battery terminal.<br />2. Cables attached to outboard motors.<br />E-9.17.11 All electrical appliances and equipment designed for permanent installation shall be securely mounted to the boat's structure.<br />E-9.17.12 Wiring Connections<br />E-9.17.12.1 All connections shall be in locations protected from the weather, or in weatherproof enclosures, or shall be watertight. If connections are exposed to immersion they shall be watertight.<br />E-9.17.12.2 Wiring connections shall be designed and installed to make mechanical and electrical joints without damage to the conductors.<br />E-9.17.12.3 Metals used for terminal studs, nuts, and washers shall be corrosion resistant and galvanically compatible with the conductor and terminal lug. Aluminum and unplated steel shall not be used for studs, nuts, and washers.<br />E-9.17.12.4 Each conductor splice joining conductor to conductor, conductor to connectors, and conductor to terminals shall be able to withstand a tensile force equal to at least the value shown in Table XIII for the smallest conductor size used in the splice for a one minute duration and not break.<br />E-9.17.12.5 Terminal connectors shall be the ring or captive spade types. See Figure 14.<br />EXCEPTION: Friction type connectors may be used if<br />a. the voltage drop from terminal to terminal does not exceed 50 millivolts for a 20 amp current flow, and<br />b. the connection does not separate if subjected to a six pound (2.75kg) tensile force along the axial direction of the connector for one minute.<br />E-9.17.12.6 Connections may be made using a set screw pressure type conductor connector providing a means is used to prevent the set screw from bearing directly on the conductor strands.<br />E-9.17.12.7 Twist-on connectors, i.e., wire nuts, shall not be used.<br />E-9.17.12.8 Solder shall not be the sole means of mechanical connection in any circuit. If soldered, the connection shall be so located or supported as to minimize flexing of the conductor where the solder changes the flexible conductor into a solid conductor.<br />EXCEPTION: Battery lugs with a solder contact length of not less than 1.5 times the diameter of the conductor.<br />NOTE: When a stranded conductor is soldered, the soldered portion of the conductor becomes a solid strand conductor and flexing can cause the conductor to break at the end of the solder joint unless adequate additional support is provided.<br />E-9.17.12.9 Crimp-on connectors shall be attached with crimping tools designed for the connector used, and to produce a connection that meets the requirements of E-9.17.12.4.<br />E-9.17.12.10 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.<br />E-9.17.12.11 Ring and captive spade type terminal connectors shall be the same nominal size as the stud.<br />E-9.17.12.12 Conductors terminating at switchboards, in junction boxes, or fixtures shall be arranged to provide a length of conductor to relieve tension, to allow for repairs, and to permit multiple conductors to be fanned at terminal studs.<br />E-9.17.12.13 The shanks of terminals shall be protected against accidental shorting by the use of insulation barriers or sleeves.<br />EXCEPTION: The shanks of terminals used in grounding systems.<br /><br />TABLE XII - ENGINE AND ACCESSORY WIRING COLOR CODE<br /><br />COLOR ITEM USE <br /><br />Yellow w/red stripe (YR) <br />Starting circuit <br />Starting switch to solenoid <br /><br />Brown/yellow stripe (BY) or<br />Yellow (Y) - see note <br />Bilge blowers <br />Fuse or switch to blowers <br /><br />Dark gray (Gy)<br /><br />Navigation lights<br />Tachometer <br />Fuse or switch to lights<br />Tachometer sender to gauge <br /><br />Brown (Br) <br />Generator armature <br />Generator armature to regulator <br />Alternator charge light<br /><br />Pumps Generator<br />Terminal/alternator<br />Auxiliary terminal to light to regulator<br />Fuse or switch to pumps <br /><br />Orange (O) <br />Accessory feed <br />Ammeter to alternator or generator output and accessory fuses or switches. <br />Distribution panel to accessory switch <br /><br />Purple (Pu) <br />Ignition <br />Ignition switch to coil and electrical instruments. <br />Instrument feed Distribution panel to electric instruments <br /><br />Dark blue <br />Cabin and instrument lights <br />Fuse or switch to lights <br /><br />Light blue (Lt Bl) <br />Oil pressure <br />Oil pressure sender to gauge <br /><br />Tan <br />Water temperature <br />Water temperature sender to gauge <br /><br />Pink (Pk) <br />Fuel gauge <br />Fuel gauge sender to gauge <br /><br />Green/stripe (G/x)<br />(Except G/Y) <br />Tilt down and/or trim in <br />Tilt and/or trim circuits <br /><br />Blue/stripe (Bl/x) <br />Tilt up and/or trim out <br />Tilt and/or trim circuits <br /><br />NOTE: If yellow is used for DC negative, blower must be brown with yellow stripe.
