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أخوانى فى الله أحضرت لكم كتاب Boatowner’s Mechanical and Electrical Manual Third Edition How to Maintain, Repair, and Improve Your Boat’s Essential Systems Nigel Calder
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Contents List of Troubleshooting Charts viii List of Tables ix Preface and Acknowledgments to the Third Edition xii Preface and Acknowledgments to the Second Edition xiv Introduction 1 Chapter 1 . Establishing a Balanced Battery-Powered Electrical System 002 Introduction 4 Batteries 5 Getting Down to Specifics 16 Putting the Pieces Together 35 Summary: A Balanced System 45 Chapter 2 . Electrical Systems for Energy-Intensive Boats 046 Additional Energy Sources 48 Dual-Voltage DC Systems 57 Fuel Cells, Higher-Voltage DC Boats, and Electric Propulsion 65 Chapter 3 . Maintaining and Troubleshooting a Battery-Powered Electrical System 072 Batteries 74 Alternators 85 Voltage Regulators 104 Diodes 109 Chapter 4 . Understanding and Troubleshooting Electrical Circuits 112 Basic Concepts and Measurements 114 DC Circuits 121 AC Circuits 133 Proper Electrical Installations 157 Chapter 5 . Corrosion, Bonding, Lightning Protection, and Grounding 196 Corrosion 198 Bonding and Cathodic Protection 212 Lightning Protection 219 Grounding 231 Chapter 6 . Battery Chargers, Inverters, Wind and Water Generators, and Solar Panels 236 Battery Chargers 238 Inverters 250 Wind and Water Generators 266 Solar Panels 281 Chapter 7 . AC Generators, DC Generators, Electric Motors (DC and AC), and Electric Lights 288 AC Generators 290 DC Generators 305 Electric Motors 306 Electric Lights 326 Chapter 8 . Marine Electronics: Antennas and Radio Grounds, Electromagnetic and Radio Frequency Interference, and Saving Soaked Equipment 338 Marine Electronics 340 Antennas and Radio Grounds 343 Electromagnetic and Radio Frequency Interference 353 Saving Soaked Equipment 360Chapter 9 . Diesel Engines: Operation and Maintenance, Troubleshooting, and Winter Layup 362 Operation and Maintenance 364 Troubleshooting Part 1: Failure to Start 377 Troubleshooting Part 2: Operating Problems 395 Winter Layup and Recommissioning 414 Chapter 1 0 . From Transmission to Propeller 422 Transmissions and Shaft Brakes 424 Connecting a Transmission to a Propeller Shaft 437 Shaft Seals 442 Struts, Bearings, and Propellers 449 Chapter 1 1 . Refrigeration and Air-Conditioning 458 CFCs and the Ozone Hole 460 Balancing Refrigeration Needs with Boat Use 463 Air-Conditioning 488 Refrigeration and Air-Conditioning: Maintenance, Troubleshooting, and Repair 491 Charging and Topping-Off Procedures 509 Chapter 1 2 . Tanks, Plumbing, Toilets, and Through-Hull Fittings 516 Tanks and Fittings 518 Plumbing 527 Marine Toilets (Heads) 540 Through-Hulls and Seacocks 560 Chapter 1 3 . Pumps and Watermakers 570 Pumps 572 Pump Switches 601 Watermakers 607 Chapter 1 4 . Steering Systems, Autopilots, and Wind Vanes 620 Steering Systems 622 Autopilots 647 Wind Vane Self-Steering 653 Chapter 1 5 . Stoves, Cabin Heaters, Gas-Powered Water Heaters, and Lanterns 662 Gas 664 Alcohol, Kerosene, and Diesel Appliances 676 Carbon Monoxide Poisoning 684 Chapter 1 6 . Blocks, Winches, Windlasses, and Bow Thrusters 692 Blocks 694 Winches 699 Windlasses 709 Bow Thrusters 729 Chapter 1 7 . Spars, Standing Rigging, and Roller Reefing 730 Spars 732 Standing Rigging 748 Roller Reefing and Furling 767 Glossary 782 Appendix A: Checklist of Winterizing Procedures 790 Appendix B: Freeing Frozen Parts and Fasteners 792 Appendix C: Tools and Spare Parts 794 Appendix D: Useful Tables 797 Index 805 oil pump full-flow filter to engine oil galleriesList of Troubleshooting Charts Chart 3-1. Battery/Alternator/Regulator Problems: Undercharging 93 Chart 3-2. Battery/Alternator/Regulator Problems: Overcharging 94 Chart 3-3. Battery/Alternator/Regulator Problems: No Alternator Output 98–99 Chart 4-1. Tests with a Voltmeter 127 Chart 4-2. Circuit Tests with an Ohmmeter 128 Chart 4-3. Equipment Tests with an Ohmmeter 128 Chart 4-4. Testing for Short Circuits with an Ohmmeter 129 Chart 4-5. Testing for Ground Leaks 131 Chart 6-1. Battery Charger Problems: No Output 247–48 Chart 6-2. Wind Generator Output Problems 279 Chart 6-3. Solar Panel Problem: No Apparent Output 287 Chart 7-1. Armature-Type AC Generators: No Output 298 Chart 7-2. Starting Circuit Problems: Engine Fails to Crank 318 Chart 8-1. Electronic Equipment Problems: Unit Will Not Come Online 341 Chart 8-2. Electronic Equipment Problems: Unit Comes On but Gives No Data or Incorrect Data 341–42 Chart 9-1. Diesel Engine Problems: An Overview 376 Chart 9-2. Diesel Engine Problems: Engine Cranks but Won’t Fire 383 Chart 9-3. Overheating on Start-Up 399 Chart 9-4. Overheating in Operation 400 Chart 9-5. Smoke in Exhaust 402 Chart 10-1. Transmission Problems 433 Chart 11-1. Refrigeration and Air-Conditioning Problems: A Brief Overview 497 Chart 13-1. Flexible Impeller, Vane, and Rotary Pump Problems: No Flow 587 Chart 13-2. Centrifugal Pump Problems: No Flow or Reduced Flow 591 Chart 14-1. Wheel Steering Failures: Rack-and-Pinion 637 Chart 14-2. Wheel Steering Failures: Cable and Pull-Pull 637 Chart 14-3. Wheel Steering Failures: Hydraulic 646 Chart 16-1. Electric Windlass: Failure to Operate 726 VIIIList of Tables Table 1-1. Summary of Pros and Cons of Different Battery Technologies 15 Table 1-2. Life Cycles Versus Depth of Discharge for East Penn Gel-Cells and AGMs 15 Table 1-3. Typical Power Consumption of Electrical Loads (12 Volts) 17 Table 1-4. Daily Power Requirements (12 Volts) of a Hypothetical Cruising Boat Anchored Off a Bahamian Beach 18 Table 1-5. Cycle Life of Trojan Industrial Batteries 19 Table 1-6. Typical KKK Alternator Outputs as a Function of Speed of Rotation and Temperature 24 Table 1-7. Horsepower Ratings for 3VX Super HC Molded Notch V-Belts (approximately 3⁄8 in. belts) 27 Table 1-8. Horsepower Ratings for 5VX Super HC Molded Notch V-Belts (between 1⁄2 in. and 5⁄8 in.) 27 Table 1-9. Horsepower Ratings for AX-Section Tri-Power Molded Notch V-Belts (1⁄2 in. belts) 27 Table 1-10. Gassing Voltages for a 12-Volt Battery as a Function of Electrolyte Temperature 33 Table 1-11. Recommended Temperature-Compensated Charging and Float Voltages for East Penn Gel-Cells 34 Table 1-12. Recommended Temperature-Compensated Charging and Float Voltages for East Penn AGMs 34 Table 1-13. Designing Your Boat’s DC Electrical System 44 Table 3-1. Electrolyte Freezing Point as a Function of Battery State of Charge 76 Table 3-2. Electrolyte Specific Gravity as a Function of Temperature and Battery State of Charge 80 Table 3-3. Typical Specific Gravity Variations by Region 80 Table 3-4. Open-Circuit Voltage Versus State of Charge for East Penn Wet-Cell, Gel-Cell, and AGM Batteries 81 Table 4-1. Common Electric Cables Acceptable to the ABYC (U.S.) 159 Table 4-2. ABYC DC Color Coding 160 Table 4-3. ABYC Color Codes for Engines and Accessory Wiring 160 Table 4-4A. Allowable Ampacity of Conductors (ABYC) 162 Table 4-4B. Allowable Ampacity of Conductors (adapted from the ISO standard) 163 Table 4-5. Conductor Sizes for 10% Drop in Voltage (ABYC) 164 Table 4-6. Conductor Sizes for 3% Drop in Voltage (ABYC) 165 Table 4-7. Conversion of American Wire Sizes to European Standards 167 Table 4-8. European-Style Volt Drop Table 168 Table 4-9. AIC Ratings for AC Circuit Breakers 181 Table 4-10. AIC Ratings for DC Circuit Breakers 181 Table 5-1. Galvanic Series of Metals in Seawater 199 Table 5-2. Weight of Zinc for Cathodic Protection of Boats 216 Table 5-3. Clamping Voltage and Time as a Function of Surge Current for a Sample TVSS Device 229 IXTable 6-1. Typical AC Appliance Loads 260 Table 6-2. Typical Loads for Induction Motors 260 Table 6-3. Sample Load Calculations 260 Table 6-4. Sizing DC-to-AC Inverters 261 Table 7-1. Typical Generator Speeds, Frequencies, and Voltages 295 Table 7-2. Typical Running Amperages for 120-Volt Induction Motors 311 Table 8-1. VHF Antenna Range in Nautical Miles 345 Table 8-2. Minimum Horizontal Spacing (in feet) Between Antennas for Different Types of Radio-Based Equipment 347 Table 8-3. Representative Loss (Attenuation) in dB per 100 Feet of 50-Ohm Coaxial Cable 347 Table 8-4. Representative Loss (Attenuation) in dB per 100 Feet of 75-Ohm Coaxial Cable 348 Table 8-5. Maximum Acceptable Signal Losses 348 Table 8-6. Calculating Signal Losses for a VHF Radio Antenna Cable 349 Table 8-7. Connector Types and Their Suitability for Different Equipment 350 Table 9-1. Basic Preventive Maintenance for Marine Diesel Engines 369 Table 9-2. Pressure Conversion Factors 404 Table 11-1. Properties of Popular Icebox Insulation Materials 465 Table 11-2. Heat Influx per 24 Hours per Square Foot of Interior Icebox Surface Area 470 Table 11-3. Sample Test Results and Calculations 474 Table 11-4. Danfoss BD50 Vital Statistics: Capacity in Btu per Hour (watts in parentheses) 479 Table 11-5. Danfoss BD50 Vital Statistics: Btu of Heat Removed per Watt-Hour of Energy Consumed 480 Table 11-6. Danfoss BD50 Vital Statistics: Current (amp) Consumption at 12 Volts 480 Table 11-7. Pressure-Temperature Chart for HFC-134a 494 Table 12-1. Pipe Sizes 528 Table 12-2. Size Relationships 529 Table 13-1. Chemical Compatibility for Impellers 576 Table 13-2. Pump Types and Common Applications 577 Table 13-3. Resistance of Various Common Fittings (expressed as feet of pipe) 578 Table 13-4. Resistance per Foot of (Old) Pipe (expressed as feet of head) as a Function of Pipe Size and Water Flow Rate 578 Table 13-5. Total Head Pressure 579 Table 13-6. Flooding Rates (gpm) of Various Size Openings at Various Depths 581 Table 13-7. Flooding Rates (gpm) of Various Size Openings at Various Depths, Assuming a Seacock with a 1-Foot Hose in Place 581 Table 13-8. Flow Rate (gph) at Specified Head Pressure, with Smooth-Bore and Corrugated-Bore Hoses 585 Table 13-9. Average Pump Life 585 Table 14-1. Hydraulic Oil Recommendations 644 XTable 15-1. LPG Cylinder Pressures in PSI as a Function of Ambient Temperature and Gas Composition 664 Table 15-2. Propane Flow as a Function of Tubing Length and Diameter 671 Table 15-3. Carbon Monoxide Poisoning Symptoms 685 Table 16-1. Block Loading as a Function of Turning Angle 695 Table 16-2. Loads on the Adjusting Tackle for Headsail Cars 696 Table 16-3. Approximate Chain Dimensions (U.S.) 713 Table 16-4. Windlass Current Draw Versus Load 722 Table 16-5. Conductor Sizes for 10% Voltage Drop at 12 Volts 722 Table 17-1. Spar Maintenance Checklist 746 Table 17-2. Breaking Loads for Stainless Steel Wire Rope 749 Table 17-3. Rigging Checklist 757 Table D-1. Fraction, Decimal, and Metric Equivalents 797 Table D-2. Inches to Millimeters Conversion Table 798 Table D-3. Torque Conversion Table, Pound Feet to Newton Meters 798 Table D-4. Feet to Meters Conversion Table 799 Table D-5. Meters to Feet Conversion Table 799 Table D-6. Inches to Centimeters Conversion Table 799 Table D-7. Degrees Fahrenheit to Degrees Celsius/Centigrade Conversion Table 800 Table D-8. Nautical Miles to Kilometers Conversion Table 801 Table D-9. Kilowatts to Horsepower Conversion Table 802 Table D-10. Pounds per Square Inch to Kilograms per Square Centimeter Conversion Table 803 Table D-11. Pound Feet to Kilogram Meters Conversion Table 803 Table D-12. Comparative Sheet Metal Thicknesses 803 Table D-13. Equivalencies INDEX 805 Numbers in bold refer to pages with illustrations A absorbed glass mat batteries. See AGM (absorbed glass mat) batteries absorption phase, 29–30, 32–33 ABYC. See American Boat and Yacht Council (ABYC) AC circuits, 2–3, 133–56; color codes, 145–46; galvanic corrosion and, 135, 137, 200; galvanic isolation, 137–39, 141, 143–44; grounding circuits, 134–37, 141, 142, 144, 232; leaks, 138–39, 152, 153, 208, 218; loads, 49–50, 258–59, 260; polarity testers, 149–50; receptacles, 150–51; ship-to-shore transfer switch, 151; singlephase circuits, 145–51; testing, 151–54, 156. See also circuit breakers AC compressors, 475, 499 accumulator tanks, 606 AC current, 85, 238 AC generators, 290–305; battery chargers and, 242; cogeneration, 53–54; features, 294; maintenance, 294–95, 303; operational principles, 290–94; setup, 133, 134; troubleshooting, 295–303, 297, 298, 299, 300, 301, 302; types of, 291–94; use of, 48–49, 51, 67; variable-speed technology, 303–5 AC refrigeration, 472, 475–76 AC ripple voltage, 97, 241 AC watermakers, 613 Adaptive Energy Optimizer (Danfoss), 481–82, 486 aerials. See antennas aft-hung rudders, 622–23 AGM (absorbed glass mat) batteries, 8, 14–16; charging, 239, 241, 245; problems with, 9, 84, 85; reliability of, 12, 257; temperature and, 75 AGS (automatic generator start) devices, 56–57 Ah (amp-hours), 4, 13 AIC (ampere interrupting capacity), 181–82 air-conditioning systems: installation, 288–89, 458–59, 490–91, 662–63; maintenance, 495–96; operational principles, 493, 495; options, 488–89; power demand of, 67; pressures, 498; sizing, 489–90 air-conditioning system troubleshooting and repair, 496–509; clutch replacement, 501–4; coolingwater differentials, 496–97; failure to run, 498–504; leak detection, 498; pressures, 497–98; sight glass, 496; superheat adjustments, 507–9; unit cuts an and off, 504; unit fails to cool, 504–7, 506 air-cooled condensers, 484–85, 497, 505 Air Head toilets, 558 air switches, 604 alcohol, 676 alcohol appliances: burners, 678–81; carbon monoxide formation, 686–87; stoves, 677–78 alloys, 200–203 Alston, Kevin, 467 alternating current. See AC entries alternators, 4, 45, 86–87; belts, 26, 27–28, 89–91, 90; charging battery banks, 37–41; construction, 86, 88; diode testing, 97–99; dual-voltage DC systems, 62–64; horsepower requirements, 26; ignition-protected alternators, 24, 87; installation, 24, 25–26, 37, 38, 72–73, 88–91; interference, 355, 358–59; isolated-ground alternators, 87; maintenance, 88–91; operational principles, 85–88; output, 23–24, 25, 26, 104–5; overcurrent protection, 190; pulleys, 24–25, 27–28, 89–90; repairing, 99–104; speed of rotation, 24–25 alternators, troubleshooting: no output, 94–99; overcharging, 94; undercharging, 91–93 aluminum, 199, 201, 205–6 aluminum hulls, 215, 216, 217, 568–69 aluminum seacocks, 562 aluminum spars and spreaders, 737–43, 746 aluminum tanks, 520–21, 523 American Boat and Yacht Council (ABYC) standards, 536; batteries, 35; battery chargers, 243; battery isolation switch, 42; bearings, 450; cables, electrical, 157–58, 159, 161, 162–63, 175, 178; capacitors, 139; carbon monoxide alarms, 689; circuit breakers, 149, 184, 193–94; connectors and terminals, 170, 178–79, 181; corrosion protection, 215, 217; distribution panels, 179, 180; electrical circuits, 70, 233; electric motors, 184–85; electromagnetic compatibility, 340; fuel hoses, 537; galvanic isolation, 139, 143–44; gas appliances, 665, 668, 669, 670, 671, 673, 678, 684; graphite packing tape, 444; ground fault circuit breakers, 140; grounding circuits, 144; heating systems, 683; hoses, 533, 538; isolation transformers, 144, 146; lightning protection, 219, 223–24, 226; motors, 583; overcurrent protection, 188–90; receptacles, 151; reverse polarity indicating device, 150; seacocks, 560–61, 564; shaft seals, 442, 443; shore power, 146, 147; switches, 602; tanks, 518, 520, 521, 525, 527; voltage drop tables, 164, 165, 168 American Petroleum Institute (API), 366–67 American Wire Gauge (AWG), 164, 166 ammeters, 17, 42, 43, 116, 310 ampacity of cables, 161–64, 184 amperage (amps), 85; ampsto-watts conversion, 17; measuring, 116, 118, 119–20, 310–11, 321; shore power choices, 149; water system analogy, 114–16 ampere interrupting capacity (AIC), 181–82 Indexamp-hour meters, 82–83 amp-hours (Ah), 4, 13 anchor lights, 55, 336, 337 anchor lockers, 709, 710 anchor windlasses. See windlasses antennas, 227, 230; features, 343; gain, 343–45, 344; installation, 346–51; types of, 343, 345–46, 756 API (American Petroleum Institute), 366–67 arcing faults, 148 armature-type AC generator, 291, 293–94, 296–99 austenitic stainless steel, 202–3, 204, 205 automatic generator start (AGS) devices, 56–57 Automatic Power Selector (Newmar), 342 Automatic Start Up (Isotherm), 481, 482, 486 automotive batteries, 4–5, 9–11, 10 autopilots, 620–21, 647–53 auxiliary rudders, 655, 656 AWG (American Wire Gauge), 164, 166 B B & R rigs, 764 backstays, 345–46, 756, 763, 770–71 baffles, 524, 526, 527 balancing a boat, 660 ball-and-socket terminals, 756, 757 ball valves, 548, 552, 562, 566, 567 Balmar generator, 56 Barient winches, 705–6 Barrier Ultra-R vacuum insulation panels, 466, 467, 470, 472, 473–75 batteries, 19; ABYC standards, 35; capacity, 6, 13, 18–22; choosing, 14–15, 16–17; conditioning, 12, 15, 33, 84–85; construction, 5; discharge, 10–11, 13, 15, 18–19, 35, 256–58, 257; electrolytes in, 5, 6–8, 9, 12, 14–16, 31, 33; equalization, 12, 15, 33, 84–85; explosions, 22; failure modes, 8–9, 10; gassing, 7, 9, 14, 15, 31; installation, 70, 74, 76–78, 183; ISO standards, 35; life cycles, 10–11, 15, 19, 35; maintenance, 72–73, 74–78, 75, 76; monitoring and control, 41–43; operational principles, 5–6; overcharging problems, 31, 94, 109; plates, 5–6; problems with, 83–85, 93, 94, 98–99; safety issues, 74; temperature and, 13, 76, 78; testing, 78–83, 79, 80, 81, 82; undercharging problems, 91–93, 107–9, 108 batteries, types of, 187; automotive, 4–5, 9–11, 10; cranking, 4, 9–11, 10, 35, 36–37, 45, 187; deepcycle, 5, 10–11, 35, 257; marine, 4–5, 10–11 battery banks, 19–22; charging, 35–41; parallel connection, 20–22, 35; series connection, 20–22; 12/24- volt DC system, 58–64 battery boxes, 74, 76–78 battery chargers, 67, 236–37, 238–50; ABYC standards, 243; AC generators and, 242; converters as, 61, 62, 63; features, 241–42, 244–46; installation, 243; interference, 359–60; inverters as, 258; as isolation transformer, 52, 53; operational principles, 238; output, 239, 240, 244, 249; overcurrent protection, 190; power factor, 242; size, 245; specifications, 242; troubleshooting, 246–50, 248, 249; types of, 238–41, 245; voltage regulation, 240–41 battery charging, 30–31; absorption phase, 29–30, 32–33; battery banks, 35–41; bulk charge, 29–30, 31–32, 33, 240, 245; charge acceptance rate, 19, 23, 29, 31, 33, 51; DC-to-AC inverters, 258; float charge, 33, 34, 240, 244, 245, 285; temperature and, 33, 34, 70; trickle charge, 239; water tank analogy, 28–30, 31–32 battery isolation/selector switches, 37–38, 42, 72–73, 186, 187, 338–39 battery paralleling relays, 39–40, 43, 45, 62, 63, 64 battery tester, 79, 80, 81–82 BC5W2 oil-resistant cable, 158, 159 bearings: ABYC standards, 450; alternators, 90–91; Cutless bearings, 422–23, 424, 449–51; preloaded thrust bearings, 435; pulley-end bearing, 90; replacement, 587–88; roller reefing and furling, 769–72; rubber sleeve bearings, 422–23, 424, 449–51; rudder bearings, 631–33; self-aligning bearings, 632; thrust bearings, 426, 435, 441, 442 bearing tubes, 633–34 bearing-type block, 695 behind-the-mast reefing, 778–81, 779, 780 bellow seals, 634–35 bellows switches, 726 below-the-waterline hoses, 534–35, 537 belt-driven compressors, 458–59, 476, 495, 496 belt-driven VST generators, 304, 305 belts, 26, 27–28, 89–91, 90, 495 Beneteau 57, 326 bevel box, 626–27 bevelheads, 624, 626–27 bilge pumps: alarms, 584; centrifugal pumps, 579–84; choosing, 575, 577; electrical circuits, 582–84; electronic circuit breaker, 194; failures, 584, 606; flooding rates, 581, 583; installation, 288–89, 516–17, 570–71; locked rotor conditions, 583; overcurrent protection, 583; shutdown requirements, 583–84; switches, 208–9, 603–7; testing, 585 bilge sump, 518, 519 biological digesters, 556–58 black pipe, 530 bladder tanks, 526 Blakes toilet, 548 BLDC (brushless DC) motors, 66–68, 70–71 Blissfield compressors, 501, 504 blocking diodes, 283–84 blocks, 692–99 Blueboard, 467, 473, 474, 475 BMEA (British Marine Electronics Association), 353 bonding circuits: air-conditioning systems, 491; installation, 196–97, 213–14, 232, 233; interference, 358; purpose of, 212–14; testing, 218; through-hulls and seacocks, 562–63 booms, 730–31, 744, 781 806 INDEXbosun’s chair, 636 bowsprits, 736 bow thrusters, 41, 729 brake band, 425 brass, 186, 199, 201, 205–6, 562 bridge rectifiers, 87, 88, 292, 297 British Marine Electronics Association (BMEA), 353 bronze, 186, 198, 204, 205–6, 207, 216, 218, 562, 569 Brunton Autoprop, 457 brushes, 86, 103; maintenance, 91; repairing, 100–102 brushless AC generators, 292–93, 300–303, 301, 302 brushless alternators, 86 brushless DC (BLDC) motors, 66–68, 70–71 brush spring, 91 bulk charge, 29–30, 31–32, 33, 240, 245 burners: alcohol, kerosene, and diesel, 677, 678–81; gas appliances, 672–75 bus bars, 180–81, 185, 186, 187, 263 butane. See gas bypass valves, 643 C cabin heaters: carbon monoxide formation, 686–87; diesel and kerosene, 677, 682–84, 683; gas, 674; installation, 662–63 cable clamps, 641, 750, 757 cables, electrical, 157–68; ABYC standards, 157–58, 159, 161, 162–63, 175, 178; ampacity, 161–64, 184; color codes, 160; construction, 157–58, 160, 166; cost, 57–58, 64; data, 193; equalizer vs. converter installation, 59–60; European cablesizing procedures, 167, 168; installation, 175–79, 176, 177, 178, 185; ISO standards, 157–58, 159, 161, 162–63, 178; labeling, 158, 159; size, 57–58, 160–61, 166; three-cable boat, 192–95; UL standards, 158, 159, 166; U.S. Coast Guard standards, 159; voltage drop and, 164–68; weight, 57–58, 64 cable steering, 627, 628, 637, 638–41 calcium buildup, 546–47 cam cleat, 695 Campingaz cylinders, 665–66 capacitive coupling, 117–18 capacitors, 138–39, 298–99, 499 capacitor-start motors, 308 capacity testing, 82 capillary tubes, 486, 506 cap shrouds, 736, 761, 762, 763, 764, 765 captive-air accumulator tanks, 606 carbon-ceramic seals, 575, 588, 589 carbon dioxide, 462, 664 carbon fiber spars, 226–27, 743–45, 746 carbon monoxide, 664 carbon monoxide alarms, 688–91, 690 carbon monoxide poisoning, 684–88, 689 carbon-silica aerogel core material, 466, 467 Castlok terminals, 751, 752 catamarans, 232, 629 cathodic disbondment, 217 cathodic protection, 214–19 CE (Conformité Européene)- marked equipment, 228, 245, 340, 342 central bonding straps, 233 centrifugal pumps: applications, 577; chemical compatibility, 575; installation, 490–91, 574, 577–84; operational principles, 573; performance, 579, 580; troubleshooting, 591–92 CFCs (chlorofluorocarbons), 460, 461–62 chain, 712–14, 713 chain lockers, 709, 710 chainplates, 730–31, 757–58, 760 charge acceptance rate, 19, 23, 29, 31, 33, 51 charge-divert regulators, 271–72, 273 chart lights, 333 check valves, 582, 643, 677 check valve wrench, 677, 678 chemical compatibility, 575, 576 chilled-water circuits, 491 chlorinated polyvinyl chloride (CPVC) pipe, 531 chlorofluorocarbons (CFCs), 460, 461–62 chromium, 199, 202, 203, 522 circuit breakers: ABYC standards, 149, 184, 193–94; ampere interrupting capacity (AIC), 181–82; electronic, 194; ground fault circuit breakers, 140; installation, 180, 181; ISO standards, 149, 192; performance, 191–92; remotely operated, 192–94; size, 183–84; smart, 194, 606; two-pole breakers, 149 clamping voltage, 228 Clark Pump (Spectra), 609, 610, 611, 612 Clean Air Act (1990), 461 clevis pins, 759 Climate Control compressors, 501, 504 clutches: adjustments, 429, 430–31, 432; Blissfield, 501, 504; Climate Control, 501, 504; forward, 424, 425, 426; Hurth adjustments, 432; installation, 422–23; maintenance and troubleshooting, 589–91; replacement, 501–4; reverse, 424, 425, 426; Sanden, 501–4; Sanden clutch, 500; slipping, 433; wheel clutch, 641, 642 CNG (compressed natural gas), 538, 664–65, 674 coaxial cable, 157, 346–51 Code of Federal Regulations (CFR), 518 Code of Practice for Electrical and Electronics Installations in Boats (BMEA), 353 coffee-grinder winches, 699 cogeneration, 53–55, 54, 256 coil-spring seals, 588, 589 cold cranking amps (CCA), 11, 13, 42 common ground point, 232–33 commutator: construction, 306; electronic commutator, 66, 71; maintenance, 311–14, 323, 324, 325 compasses, 231, 354, 640 compressed natural gas (CNG), 538, 664–65, 674 compression fittings, 529, 751–53 compressors: installation, 458–59; refrigeration cycle, 492–94, 493; speed, 480, 481–82, 486; troubleshooting, 505–6; vacuuming a unit, 514–15 INDEX 807compressors, types of: AC, 475, 499; belt-driven, 458–59, 476, 495, 496; Blissfield, 501, 504; Climate Control, 501, 504; Danfoss, 478, 479, 480, 486, 500; externally driven, 495, 496; hermetic, 475, 476, 486; Masterflux, 487; reciprocal, 506; Sanden, 501–4 condensates, 491 condensers: air-cooled condensers, 497, 505; air cooling vs. water cooling, 484–85; installation, 458–59; refrigeration cycle, 493–95; throughhull condensers, 484–85; troubleshooting, 505; water-cooled condensers, 497, 498, 505 conditioning batteries, 12, 15, 33, 84–85 conductive heat loss, 463–64, 465 conductivity of metals, 186 conductivity sensors, 604 cone of protection, 222–23 Conformité Européene(CE)- marked equipment, 228, 245, 340, 342 connectors and terminals: ABYC standards, 170, 178–79, 181; cable-end fittings, 640–41; electrical, 168–75, 178–79, 181, 186; ISO standards, 170, 178–79, 181; rigging, 755–56, 757–59; rod rigging, 753–54; wire rope, 749–53 constant-cycling AC refrigeration units, 472 constant-cycling capacity calculations, 478–79 constant-cycling DC refrigeration units, 464, 478–81, 483, 484–87, 499–501 constant-velocity joints (CVJs), 441–42 control cables, 431–33 controllable-pitch propellers, 452, 457 convective heat loss, 464, 465 converter circuits, 62–65, 63, 64 converters, 58–62, 60, 61, 357 cooling circuits, 490–91 cooling-water differentials, 496–97 copper, 186, 199, 201, 206, 520, 521 copper pipe or tubing, 528–30 cored hulls, 567, 568 corrosion: ABYC standards, 215, 217; blocks, 698–99; bonding circuits, 212–14, 213; cathodic protection, 214–19; cleaning up, 206; crevice corrosion, 201, 203, 204, 206, 760; electrical circuits and, 122–23, 135, 137, 157, 208; electrolytes and, 198–201, 203, 205, 206, 215; paint and, 206, 207, 217; pitting corrosion, 201, 202, 204, 206; rigging, 759–60; saildrives, 428; stray-current corrosion, 207–12, 218; through-hulls and seacocks, 562; windlasses, 710–11. See also galvanic corrosion corrosion and grounding test procedures, 234–35 corrosion fatigue, 204, 205 cotter pins, 759 coupling puller, 434 couplings, 434–35, 437–41, 438, 439, 440 CPVC (chlorinated polyvinyl chloride) pipe, 531 Crane shaft seal, 446 cranking batteries, 4, 9–11, 10, 35, 36–37, 45, 187 crevice corrosion, 201, 203, 204, 206, 760 cross-linked polyethylene, 525 CRT displays, 360 current clamp, 119–20 Cutless bearings, 422–23, 424, 449–51 CVJs (constant-velocity joints), 441–42 D daily load calculation, 17–18 Danfoss: Adaptive Energy Optimizer (AEO), 481–82, 486; compressors, 478, 479, 480, 481, 486, 500 data bus, 193, 195 data cables, 193 DC circuits, 2–3, 121–33; adequacy of, 45; battery capacity requirements, 18–22; charging capabilities, 22–26; common ground point, 232–33; corrosion and, 122–23, 208; design worksheet, 44; dual-voltage, 57–65; grounded circuits, 231–32; ground faults, 130–32; ground-return circuits, 121–23; heating systems, 684; high-capacity, 21, 35, 483, 485; insulated-return circuits, 122–23; leaks, 218; load calculation, 17–18, 20, 46–48, 51, 55, 260; monitoring and control, 41–43; ohmmeter troubleshooting, 127–30; safety standards, 70; short circuits, 129–30; sizing, 44, 45; voltage regulation, 28–35; voltmeter troubleshooting, 123–27; windlasses, 722–24, 725 DC current, 85 DC generators, 53, 55–57, 56, 68–71, 190, 305 DC motors, 495 DC refrigeration units: constant-cycling units, 464, 478–81, 483, 484–87, 499–501; high-capacity holding-plate units, 483, 485–86, 487; holding-plate units, 476, 483, 485–86, 489; refrigeration load, 480 DC-to-AC inverters, 4, 67; batteries and, 36, 256–58; cogeneration, 53–55, 54; features, 254–56; installation, 259, 262–64; inverter-based boats, 49–53; load calculation, 55, 261; operational principles, 250–51; troubleshooting, 264–66; types of, 251–53; waveform choices, 251–54 DC watermakers, 613 deck washdown pumps, 575, 577 Deep Creek Design lighting, 337 deep-cycle batteries, 5, 10–11, 35, 257 depth sounders, 338–39 Detroit Diesel engines, 385, 392 diaphragm lift pumps, 393–95 diaphragm pumps: applications, 575, 577; electric diaphragm pumps, 575, 598–601; manual diaphragm pumps, 595–98; operational principles, 573; running dry, 574; troubleshooting, 595–601 diesel, 676–77 diesel appliances: burners, 678–81; carbon monoxide 808 INDEXformation, 686–87; drippot stoves, 677, 681–82; heating systems, 682–84, 683; tanks, 677–78 diesel/electric boats, 69, 71 diesel engines: engine surveys, 416–21; maintenance, 362–63, 368–77; operational principles, 364–68; recommissioning, 416; winter layup, 414–16, 415 diesel engines, troubleshooting, 376; airflow problems, 382–83; compression, 385–86; engine instrumentation, 409–14; engine runaway, 405–6; engine won’t fire, 382–95; exhaust back pressure, 403, 404; failure to crank, 377–82, 378, 379, 380, 381; failure to shut down, 405–6; fuel problems, 386–88; fuel systems, bleeding, 388–93, 389, 390, 391; ignition temperatures, 383–85; knocks, 403; loss of performance, 403–5; misfiring, 405; oil pressure, 407–8; overheating, 395–401; smoke, 401–3; turbochargers, 408–9; water in the crankcase, 406–7; water in the engine, 378–81, 382 diesel tanks, 519, 525–27, 526 diodes: alternators, 86–87, 88, 89; blocking diodes, 283–84; brushless generators, 301–2; heat sinks, 110–11; identification, 109–10; installation, 72–73; isolation diodes, 95, 110–11; reverseavalanche silicon diodes, 88–89; snubbers, 88–89; split-charging diodes, 38–39, 92; testing, 97–99, 111, 118, 120–21, 301, 302 direct current. See DC entries distributed power systems, 193, 195 distribution panels, 179–82, 183–84 Dole Refrigerating Company holding plate, 477 double-acting piston toilets, 547–53, 548, 549, 550, 551, 552 downwind poles, 745–48, 746 drag link, 637–38 drinking water hoses, 537 dripless packing, 444–45, 449 drip-pot stoves, 677, 681–82 dual-station control cables, 431–33 dual-voltage DC systems, 57–65 duplex stainless steel, 202, 207 dynamic rig tensioning, 764–65 E earth leaks, 130–32, 152, 153 East Penn batteries, 34 ECBs (electronic circuit breakers), 194 ECCP (European Climate Change Programme), 462 8D batteries, 19 electrical circuits: ABYC standards, 70, 233; bilge pumps, 582–84; conservative wiring, 161; ISO standards, 233; lightning protection, 227–30, 231; troubleshooting, 112–13; water system analogy, 114–17. See also AC circuits; DC circuits electric clutches, 590, 591 electric diaphragm pumps, 575, 598–601 electric motors: ABYC standards, 184–85, 583; interference, 359; operational principles, 306–8; overcurrent protection, 184–85; speed regulation, 308–9; troubleshooting, 309–15, 310, 312, 314. See also starter motors electric propulsion, 65–71, 66, 67, 68, 69 electric shock, 134–35, 141 electric toilets, 553–55, 577 electric windlasses, 710, 719–26, 720, 721, 723, 724, 725 electrified double-acting piston toilets, 552–53 electrolytes: in batteries, 5, 6–8, 9, 12, 14–16, 31, 33; corrosion and, 198–201, 203, 205, 206, 215; seawater as, 135, 137 electromagnetic compatibility (EMC), 340 electromagnetic interference (EMI), 245, 340; equipment installation, 196–97; prevention, 355–60, 356, 357, 359; sources of, 353–55, 354; tracking down, 355 electronic circuit breakers (ECBs), 194 electronic commutator, 66, 71 electronic equipment: batteries for, 40–41; grounding of, 196–97; installation, 46–47, 338–39; interference, 340; lightning protection, 227–31; power consumption, 17; soaked equipment, 360–61; troubleshooting, 340–43, 342; 24-volt, 58 electronic switches, 604–5 emergency steering, 646–47 Energy Transfer Device (Horizon Reverse Osmosis/Sea Recovery), 609–11 engine-driven refrigeration units, 476–78, 499, 501–4, 510 engine-driven watermakers, 613–14 engines: alignment, 438–41, 439, 440, 443, 449; alternator size and, 26; installation, 443–44, 448–49, 686; lightning protection, 227 engine surveys, 416–21 Environmental Protection Agency (EPA), 461, 462 epicyclic gearing, 722 epicyclic transmissions, 424–25, 430–31 epoxy tanks, 519 equalization bus, 233 equalization of batteries, 12, 15, 33, 84–85 equalizer circuits, 62–65 equalizers, 58–60, 59, 61 ethyl alcohol, 676 European cable-sizing procedures, 167, 168 European Climate Change Programme (ECCP), 462 European refrigerant use, 460, 461–62 evaporator plates, 478–79, 486–87 evaporators, 493–94 excitation test, 97 exciter windings, 292, 302–3 exhaust hoses, 533–34, 583 expansion valves, 493, 506–8 externally driven compressors, 495, 496 extrusions, 771–72 eye terminals, 749–50, 758 INDEX 809F fasteners: in aluminum, 738–40, 741; stainless steel, 704, 740; in wood, 733–34 FCC Rule 15, Part B, 245, 340, 342 feathering propellers, 453, 455–56, 457 ferritic stainless steel, 202–3 ferro-resonant chargers, 238, 239, 240, 244, 249 fiberglass hulls, 216, 217, 562–63, 567, 568 fiberglass marine exhaust tubing, 533 fiberglass rudders, 630 fiberglass tanks, 518, 524, 527 fiber rigging, 754–55 field winding, 85, 86 filament igniters, 673, 714–19 filtering techniques, 356–58, 357 Fischer Panda generator, 56, 294 fishhook, 639 fixed-pitch propellers, 452 flame primers, 384 flapper valves, 548, 549, 551, 552 flare fittings, 529–30 flashing the field, 96, 97, 297–98, 302–3 flexible-impeller pumps. See variable-volume impeller pumps flexible tanks, 526 Flex-O-Fold propellers, 454–55 float charge, 33, 34, 240, 244, 245, 285 float switches, 208–9, 602–3, 605, 606 flooded electrolyte batteries, 6–7 flooding rates, 581, 583 fluorescent lights, 326, 327, 329–32, 359, 662–63 flute stopper, 781 fluxgate compasses, 231, 647 folding propellers, 453–55, 454, 456–57 forestays, 730–31, 763, 768–69 fork terminals, 758, 759 four-part purchase, 698 Fourwinds generators, 269 fractional rig tuning, 764 freezers, 458–59, 479, 480, 497 Freon-12, 460–61, 462–63 Freon-22, 460, 490 frequency, 85, 238 freshwater pumps, 575, 577 freshwater tanks, 516–17 Frigoboat: couplings and tubing, 481; evaporator plates, 478–79; keel cooler, 484–85, 495; Smart Speed Control, 481–82, 486 fuel, 676–77. See also specific fuels fuel-burning appliances, 686–87. See also alcohol appliances; diesel appliances; gas appliances; kerosene appliances fuel cells, 65–66 fuel filters, 677, 681 fuel injection pumps, 388–95 fuel pumps, 577 fuel tanks and systems, 214, 677–78; hoses, 536–37; ISO standards, 214, 524, 527; pipe, 531; tanks, 518, 519, 521, 524, 525–27; U.S. Coast Guard standards, 214, 524 full-skeg rudders, 622 fuses, 183–84, 189 G gain, 343–45, 344 gaiter-type rudderstock seals, 634–35 Galley Maid Central Waste Treatment System, 559–60 galvanic cells, 199–200 galvanic corrosion: AC circuits and, 135, 137, 200; conditions for, 203, 205; electrolytes and, 198–201, 203, 205, 206, 215; galvanic cells, 199–200; galvanic series, 198–203; prevention, 53, 203–7 galvanic isolators: ABYC standards, 139, 143–44; converters used for, 61–62; corrosion and, 200, 219; location, 139, 141; operational principles, 137–39, 145; testing, 143 galvanic series of metals, 198–203 galvanized chain, 713–14 galvanized pipe, 530–31 gas: cylinder types, 665–66; hoses, 538; pressure measurement, 668, 669; refilling cylinders, 665–67, 666; safety precautions, 665; types of, 664 gas appliances: ABYC standards, 665, 668, 669, 670, 671, 673, 678, 684; gas lockers, 667–68; installation, 667–72; ISO standards, 668, 669–70, 671; troubleshooting, 672–75 gasoline engines, 358 gasoline tanks, 518, 524, 525–27, 526 gassing of batteries, 7, 9, 14, 15, 31 gassing voltage, 33 gate valves, 561, 567 gauge sets, 463, 510, 511–15 geared steering, 623–27, 624, 625, 626, 636–38 gears, 719–21 gear-type lift pumps, 394 gel-cell batteries, 7–8, 14–15; charging, 239, 241, 245; problems with, 9, 84, 85; reliability of, 12, 257; temperature and, 75, 76, 78 generators, 236–37; BLDC motors and, 66–68, 70–71; limitations of, 303; use of, 18 generators, types of: beltdriven VST generators, 304, 305; DC generators, 53, 55–57, 56, 68, 190, 305; permanent-magnet generators, 68; prop-shaft generators, 267; VST, 303–5; water generators, 266, 267. See also AC generators; wind generators genoa sheet loads, 697 Glacier Bay: holding plates, 477; hose clamps, 538; insulation, 467, 472, 473, 474–75; insulation tests, 465; Micro Blast Chiller, 488; Micro HPS system, 487–88 globe valves, 561, 567 glow plugs, 384–85 going aloft, 747 golf-cart batteries, 15 Gori three-bladed folding propeller, 456–57 The Gougeon Brothers on Boat Construction, 734 governors, 309 graphite packing tape, 444 Groco ball valve, 566 grounded circuits, 231–32 ground fault circuit breakers (GFCBs), 140 ground fault circuit interruptors (GFCIs), 140, 150 ground faults, 130–32, 152, 153 810 INDEXgrounding and corrosion test procedures, 234–35 grounding circuits, 134–37, 141, 142, 144, 196–97, 231–33 ground plates, 224–25, 232 ground-return circuits, 121–23 ground tackle, 709, 710 gudgeons, 622, 630 H half-skeg rudders, 623 Halide leak detectors, 498 halogen lights, 60, 326, 342 halyards: halyard wrap, 772–74; replacing, 742–43; spinnaker, 743; tension on, 770–71 halyard winches, 699–701 HCFCs (hydrochlorofluorocarbons), 460, 461–62 heads. See marine toilets headsails: damage, 775–76; powered headsail reefers, 776; roller furling, 777–78; roller reefing, 766–76 headsail sheet loads, 695–96 headstays, 756, 768–69 heating systems, 662–63, 674, 677, 682–84, 683, 686–87 heat removal, Btu per hour, 478–79, 480, 489–90, 496–97 Heat Shield, 473, 474, 475 heat sinks, 110–11 heeled waterline, 561 hermetic compressors, 475, 476, 486 Hertz (Hz), 85, 238 HFC-134a, 460–63, 492–94 HFC-152a, 462 HFC-404A, 462, 463 higher-voltage DC circuits: battery connections, 21, 35, 58; electric propulsion, 68–71, 69; holding-plate refrigeration units, 483, 485–86, 487; overcurrent protection, 185, 187, 188; safety issues, 70. See also dual-voltage DC systems high-frequency battery chargers, 241 high-frequency inverters, 252, 253, 258 high-frequency isolation transformers, 145 high-load tester, 81–82 high-pressure switches, 601 holding-plate refrigeration units: AC units, 472, 475–76; cooling-water differentials, 496–97; DC units, 483, 485–86, 489, 499, 500; limitations of, 476–78; troubleshooting, 509 holding plates, 458–59 holding tanks: hoses, 535–36; installation, 516–17, 541, 543–45, 544; materials, 522, 525, 526 Horizon Reverse Osmosis Energy Transfer Device, 609–11 horizontal windlasses, 714–19 horsepower requirements, 26 hose clamps, 533–34, 537, 538, 568 hoses, 532–40; ABYC standards, 533, 538; connections, 533–34, 537–38; ISO standards, 533, 535, 538; resistance effect, 578–79; sizes, 537; types and materials, 532–37; UL standards, 533 Hurth transmission, 425, 426, 429, 432, 435 hybrid inverters, 252–53 hydraulic hoses, 538–40, 539 hydraulic shaft lock, 436 hydraulic steering, 627–28, 629, 642–45, 646 hydraulic systems, 644, 727–28 hydraulic transmissions, 424, 429, 430, 431–33, 435–36 hydraulic windlasses, 726–28 Hydrocaps, 6, 33 hydrochloric acid, 546–47 hydrochlorofluorocarbons (HCFCs), 460, 461–62 hydrogen-powered fuel cells, 65–66 hydrometer, 79, 80 Hz (Hertz), 85, 238 I iceboxes, 463–72; adding a refrigeration unit, 464; construction, 468–70; heat loss calculations, 470–71; heat loss testing, 471–72; insulation, 463–68 ignition-protected alternators, 24, 87 ignition warning lights, 410–11 Imanna Laboratory, 585 impeller pumps: applications, 577; chemical compatibility, 575, 576; head pressure, 574; maintenance and troubleshooting, 584–89; operational principles, 572–73; running dry, 574–75 Imperial measurements, 577 impressed-current cathodic protection systems, 217 inboard/outboard units, 424, 427–28 incandescent lights, 326, 327, 342, 662–63 induction motors, 307–8, 309, 310–11, 315 inductors, 356–57 inertia starters, 316, 317, 320, 321 in-mast reefing, 730–31, 778–81, 779, 780 Installation Standards for Marine Electronic Equipment Used on ModerateSized Vessels (NMEA), 353 insulated-return circuits, 122–23 insulation, cable, 166 insulation, refrigerator, 463–68; improvements to, 486; superinsulation, 465–68, 466, 467; testing, 465, 473–75 interference: electromagnetic interference, 245, 340; equipment installation, 196–97; prevention, 355–60, 356, 357, 359; radio frequency interference, 241, 245, 278, 340; sources of, 353–55, 354; tracking down, 355 intergranular corrosion, 203 International Organization for Standardization (ISO) standards: batteries, 35; battery isolation switch, 42; cables, electrical, 157–58, 159, 161, 162–63, 178; circuit breakers, 149, 192; connectors and terminals, 170, 178–79, 181; distribution panels, 179; electrical circuits, 233; electromagnetic compatibility, 340; fuel hoses, 536–37; fuel tanks, 214, 524, 527; gas appliances, 668, 669–70, 671; hoses, 533, 535, 538; lightning protection, 219; seacocks, 561, 564; shore power, 146, 147; tanks, 518, 520, 521, 525 inverter-based boats, 49–53, 57 inverters. See DC-to-AC inverters INDEX 811iron, 202 ISO. See International Organization for Standardization (ISO) isolated-ground alternators, 87 isolation diodes, 95, 110–11 isolation transformers: ABYC standards, 144, 146; battery charger as, 52, 53; circuit testing, 154; corrosion prevention, 200, 219; grounding circuits, 148, 149, 589; installation, 236–37; operational principles, 144–45; testing, 246 isopropyl alcohol, 676 Isotherm: Automatic Start Up, 481, 482, 486; through-hull condensers, 484–85, 495 J Jefa: rudders, 631; steering, 624 Jeremiah, 231 Jett Head toilets, 554 joker valves, 548, 549, 551, 552 K keel cooler, 484–85, 495 keel-stepped masts, 764 kerosene, 664, 676–78 kerosene appliances: burners, 678–81, 680; carbon monoxide formation, 686–87; heating systems, 682–84; lanterns, 685; tanks, 677–78 Kevlar rigging, 754 Kiss wind generators, 268–69 KKK-rated alternators, 23, 24, 87 Kyoto Protocol, 462 L lanterns, 662–63, 685 lash compensators, 770 latent heat, 492 Lavac toilets, 555–56 leak detectors, 498 leaks: earth leaks, 130–32, 152, 153; electrical, 138–39, 152, 153, 208, 218; flooding rates, 581, 583; refrigerants, 496, 498; shaft seals, 442, 447, 448, 584; stuffing boxes, 443, 444 LectraSan MSD, 558–59 LED lights, 326, 332–37, 333, 334, 336 level switches, 602–7 lift pumps, 388–95 light-activated switches, 604–5 light-emitting diode (LED) lights, 326, 332–37, 333, 334, 336 lightning bypass, 227 lightning prevention, 230–31 lightning properties, 220–21 lightning protection, 219–31; ABYC standards, 219, 223–24, 226; antennas, 227, 230; arrestors, 227, 228; cables, 214, 223–24; carbon fiber spars, 744; catamarans, 232; cone of protection, 222–23; connections, 225; dissipators, 230; electrical circuits, 137, 227–30, 231; electronic equipment, 227–31; ground plates, 224–25; installation, 196–97; ISO standards, 219; lightning rods, 221–22; map, 220; parallel paths, 223, 225–26; path to ground, 223–27, 232, 233; powerboats, 227; rolling ball concept, 223; sailboats, 222–23; zone of protection, 222–23 lights, 326–37, 662–63; anchor, 55, 336, 337; chart, 333; fluorescent, 326, 327, 329–32, 359; halogen, 60, 326, 327–28, 342; incandescent, 326, 327, 342; LED, 326, 332–37, 333, 334, 336; power consumption, 17, 18, 20; xenon, 326, 328–29. See also navigation lights linear polyethylene, 524–25 linear transformer chargers, 238–39, 241 line cutters, 452 line-frequency inverters, 251–52, 253, 255, 258 line loads, 695–98 lip-type seals, 447–48; failures, 448; installation, 448, 635; lubrication, 447–48, 575; replacement, 588, 589; use of, 424, 449, 634 liquefied petroleum gas (LPG). See gas load, 116; calculation, 17–18, 46–48, 49–51, 55, 258–59, 260; reduction strategies, 20; testing, 81–82 load-sensing switches, 605–6 load testing, 81–82 locked rotor conditions, 184, 583 long-distance cruising, 660–61 loose neutrals, 148 low-pressure switches, 602 LPG (liquefied petroleum gas). See gas Luke fully feathering propeller, 456 M macerating toilets, 553–55 macerator pumps, 516–17, 543, 570–71 mainsails: behind-the-mast reefing, 778–81, 779, 780; in-mast reefing, 730–31, 778–81, 779, 780 mainsheet loads, 696–98, 697 Malo 45, 60, 68, 518, 710 Mamba system, 626–27 manganese bronze, 199, 206 manual diaphragm pumps, 595–98 manual propeller shaft lock, 436–37 manual windlasses, 714–19 marine batteries, 4–5, 10– 11 marine-grade alloys, 201 marine sanitation device (MSD) types, 540, 558–60, 559 marine toilets, 540–60; calcium buildup, 546–47; clogging, 546; discharge regulations, 540–41; electrified double-acting piston, 552–53; installation, 516–17, 541–45; maintenance, 545; odors, 545– 46; seat hinges, 545; winterizing, 545 marine toilets, types and troubleshooting, 540; Air Head, 558; biological digesters, 556–58; doubleacting piston, 547–53, 548, 549, 550, 551, 552; electric (macerating), 553–55; Jett Head, 554; Lavac, 555–56; Microphor, 556–58; Royal Flush, 554; Type I MSD, 558–60, 559; VacuFlush, 556, 557; vacuum, 555–56 martensitic stainless steel, 202–3 Masterflux compressor, 487 masthead boxes, 734, 736, 737, 741–42 masthead lights, 133, 334, 336 812 INDEXmasthead rigs, tuning, 761–64 masthead toggle, 756 masts, 730–31; aluminum, 738, 739, 740; bend, 740, 778, 781; carbon fiber, 226–27; chocking, 764; cutouts, 740–41, 742, 743; going aloft, 747; lightning protection, 226; maintenance, 743; rake, 761, 763; tuning a rig, 765; wooden, 222, 734, 736, 737 maximum heeled waterline, 561 maximum power point tracking (MPPT) voltage regulator, 273, 284–85 Max-Prop propeller, 455 measurement conversions, 577 mechanical seals, 445–47, 446, 449 MerCruiser inboard/outboard installations, 217 mercury float switches, 602–3 Meridian batteries, 16 metal hulls, 568–69 metal oxide semiconductor field effect transistors (MOSFETs), 193–94, 238, 239 metal oxide varistors (MOVs), 227, 229 metals: alloys, 200–203; chemical compatibility, 575, 576; conductivity, 186; galvanic series, 198–203. See also specific metals metal tanks, 519–24, 520, 521, 522, 523 metal through-hulls and seacocks, 562–63, 567 metric measurements, 577 Micro Blast Chiller (Glacier Bay), 488 Micro HPS system (Glacier Bay), 487–88 Microphor toilets, 556–58 Mid-Capacity Rule, 19 modified-sine-wave inverters, 251, 252, 253, 258 Monel, 199, 205, 206 MOSFETs (metal oxide semiconductor field effect transistors), 193–94, 238, 239 motors. See electric motors MOVs (metal oxide varistors), 227, 229 MPPT (maximum power point tracking) voltage regulator, 273, 284–85 MSD (marine sanitation device) types, 540, 558–60, 559 multimeters, 117–21, 132–33. See also ammeters; ohmmeters; voltmeters multiple-speed winches, 701–2 multistep chargers, 240–41, 245 multistep regulators, 31–35, 32, 33, 45 muriatic acid, 546–47 N Nada, 606 National Electrical Manufacturers Association (NEMA), 140 National Fire Protection Association (NFPA), 219, 224, 226 National Marine Electronics Association (NMEA), 178, 353 navigation equipment: power consumption, 17, 20; voltage requirements, 71 navigation lights: installation, 46–47, 662–63; LED lights, 334, 336; masthead, 133, 334, 336; power consumption, 17, 18, 20 NEC (U.S. National Electrical Code), 161 NEMA (National Electrical Manufacturers Association), 140 Newmar’s Automatic Power Selector, 342 NFPA (National Fire Protection Association), 219, 224, 226 nicad batteries, 16, 343 nickel, 199, 202, 203 nickel-cadmium batteries, 16, 343 Nicopress fittings, 750 Nitronic 50, 753 NMEA (National Marine Electronics Association), 178, 353 no-discharge zones (NDZ), 540–41 noise suppression, 358–60, 359 Norseman Dyform wire rope, 748, 749 Norseman terminals, 641, 751, 752 N-type alternators, 95–97, 96, 98, 103–4 nylon, 633 O offset gears, 719, 720 ohmmeters, 120, 127–30, 133 ohms, 114, 117, 118, 120–21 Ohm’s law, 117 oil, 366–67 oil-lubricated lip seals, 448 oil pressure regulating valve, 429–30 oils, refrigeration, 463, 510, 514–15 open-cable steering, 627, 639–40 open-circuit voltage, 80–81 open neutrals, 148 Optima batteries, 15–16 output-shaft seals, 434–35 overcurrent protection, 182–92; ABYC standards, 188–90; bilge pumps, 583; fuses, 183–84, 189; location, 188–90; remote switches, 193–94; U.S. Coast Guard standards, 188; windlasses, 722. See also circuit breakers ozone layer protection, 460, 461 P packing, 444–45, 449 packing glands, 422–23, 424, 442–45, 449, 633, 634 packing removal tool, 444 paints and painting, 206, 207, 217, 520 paraffin appliances, 676–81, 686–87 Paragon transmissions, 424–25, 430–31 Pardey, Larry, 736 Pardey, Lin, 736 passivated stainless steel, 201, 202, 203 PBO rigging, 754 PDMs (power distribution modules), 194 pedestal steering, 624–29, 636–42, 646 permanent-magnet generators, 68 permanent-magnet motors, 307, 312, 315 phosphoric acid, 206 photo-optic compasses, 647 Piezo igniters, 673, 675 pilot lights, 673 pintles, 622, 630 pipes and plumbing systems, 527–40; compression fittings, 529; copper pipe or tubing, 528–30; flare fittings, 529–30; (continued) INDEX 813(continued) pipes and plumbing systems: fittings, 531, 578; pipe sizes, 527–28; plastic pipe, 531–32; resistance effect, 578–79; steel pipe, 530–31 piston pumps: applications, 577; operational principles, 573; running dry, 574; troubleshooting, 592–95, 593, 594 piston-rod seals, 548, 550–51 pitting corrosion, 201, 202, 204, 206 planetary gearing, 722 planetary transmissions, 424–25, 430–31 plastic pipe, 531–32 plastics: chemical compatibility, 575, 576; water absorption, 633 plastic tanks, 524–26 plastic through-hulls and seacocks, 563–64, 567–68 plumbing. See pipes and plumbing systems plywood tanks, 519 pneumatic switches, 604 polarity testers, 149–50 polarization transformer, 144–45, 148, 149 polyethylene plumbing systems, 531–32 polyethylene tanks, 524–26, 525, 527 polypropylene tanks, 526 polyurethane tanks, 526 polyvinyl chloride (PVC) pipe, 531 positive-displacement pumps, 573, 574, 575, 577 powerboat lightning protection, 222–23, 227 power distribution modules (PDMs), 194 powered headsail reefers, 776 powered winches, 708–9 power factor, 242, 245 power requirements, 17–18, 20, 46–48 preengaged starters, 316–17, 318, 320, 321, 322–23, 325 preloaded thrust bearings, 435 prepressurized accumulator tanks, 606 pressure gauges, 411–13, 412 pressure switches, 601–2 pressure tanks, 606 Primus-type burners, 678–81 propane. See gas propeller puller, 453 propellers, 451–57; blade alignment, 452; blade pitch, 452, 456–57; controllable-pitch propellers, 457; feathering propellers, 453, 455–56, 457; folding propellers, 453–55, 454, 456–57; installation, 422–23, 453; line cutters, 452; standard propellers, 452–53 propeller shaft generators, 267 propeller shafts: couplings, 437–38; installation, 422–23, 424, 450; lip-type seals, 447–48, 449; mechanical seals, 445–47, 446, 449; shaft brakes, 435–37; shaft seals, 442–49, 584; stern tubes, 422–23, 445, 449, 450; struts, 449, 450, 451; stuffing boxes, 442–45 PSS shaft seal, 446 P-type alternators, 95–97, 98, 103–4 pulley-end bearing, 90 pulleys, 24–25, 27–28, 89–90, 495 pull-pull cable steering, 627, 628, 639, 640 pump cup washer, 678 pumpout deck fittings, 536 pumpout lines, 535–36 pumps, 584–601; applications, 577; chemical compatibility, 575, 576; choosing, 574–77; clutches, 589–91; installation, 570–71; maintenance and troubleshooting, 584–601; operational principles, 572–73; running dry, 574–75; types of, 572–73, 577. See also specific pumps pump switches, 601–7, 602, 603, 604, 605 purchase, 698 push-pull cable steering, 628, 639, 640 PVC (polyvinyl chloride) pipe, 531 Q quadrant steering, 627, 628 R R-12, 460–61, 462–63 R-22, 460, 490 R-404A, 463 R-407C, 490 R-409A, 460, 463 R-410A, 490 R-417A, 490 rack-and-pinion steering, 624–27, 636–38, 646 radar antennas, 338–39, 345–46 radial steering, 627, 629 radiated heat loss, 464–65 radio frequencies, 347, 348 radio frequency interference (RFI), 241, 245, 278, 340; prevention, 355–60, 356, 357, 359; sources of, 353–55, 354; tracking down, 355 radios: antennas, 338–39, 350–51; grounding, 233, 351–53, 352; installation, 353–54, 360 ratchet-geared windlasses, 716–17 rate gyro, 647 raw-water circuits, 583; airconditioning systems, 490–91; ball valves, 566; hoses, 534; installation, 458–59, 516–17; pumps, 577; strainer, 490–91, 546 receiver-filter-drier (RFD), 493, 494, 514 receptacles, 150–51 reciprocal compressors, 506 refrigerants: handling, 509–10; leaks, 496, 498; loss of, 505; recovery and recycling equipment, 461, 462; topping off, 462, 495; types of, 460–63, 462, 490; U.S. Coast Guard standards, 462; venting, 461 refrigeration cycle, 492–95 refrigeration gauge sets, 463, 510, 511–15 refrigeration oils, 463, 495, 510, 514–15 refrigeration systems, 55, 458–59; adding to existing icebox, 464; charging, 462; charging procedures, 498, 510, 511–15; choosing, 472, 488; heat removal, Btu per hour, 478–79, 480, 489–90, 496–97; maintenance, 495–96; operational principles, 491–95, 492, 493, 494; pipe or tubing, 528; pressures, 497; pumps, 577; topping off, 462, 509–10; vacuuming a unit, 514–15. See also iceboxes 814 INDEXrefrigeration systems, types of: AC units, 472, 475–76; constant-cycling AC units, 472; constant-cycling DC units, 464, 478–81, 483, 484–87, 499–501; DC units, 476; engine-driven units, 476–78, 499, 501–4, 510; high-capacity holding-plate DC units, 483, 485–86, 487; holding-plate AC units, 472, 475–76; holding-plate DC units, 483, 485–86, 489, 499, 500; holding-plate units, 476–78, 509; hybrid systems, 487–88 refrigeration system troubleshooting and repair, 496–509; clutch replacement, 501–4; coolingwater differentials, 496–97; failure to run, 498–504; leak detection, 498; pressures, 497–98; sight glass, 496; superheat adjustments, 507–9; unit cuts an and off, 504; unit fails to cool, 504–7, 506 relays, battery paralleling, 39–40, 43, 45, 62, 63, 64 remotely operated circuit breakers (ROCBs), 193 remotely operated switches, 192–94 reserve capacity, 13 residual current circuit breakers (RCCBs), 140 residual current devices (RCDs), 140 resistance, 114, 115–16, 117, 120–21 resistance effect, 578–79 resistance tests, 311 reverse-avalanche silicon diodes, 88–89 reverse polarity indicating device, 149–50 rheostats, 309 rigging. See standing rigging ripple voltage, 97, 241 rod rigging, 748, 753–54, 762 roller reefing and furling, 766–81; bearings, 769–72; behind-the-mast reefing, 778–81, 779, 780; booms, 781; extrusions, 771–72; halyard wrap, 772–74; headsails, 766–76, 777–78; in-mast reefing, 778–81, 779, 780; installation, 730–31; maintenance, 776–77; powered headsail reefers, 776; riding turns on the reefing drum, 774–75; sail damage, 775–76; tips, 776 rolling ball concept, 223 rope lockers, 709, 710 rotary pumps: applications, 577; chemical compatibility, 575, 576; operational principles, 572–73; troubleshooting, 587, 590, 591 rotational molding, 524 Rotolock valves, 505–6, 511–14 rotors, 85, 86, 103–4, 305 rotor windings, 292, 301–2 Royal Flush toilets, 554 rubber-plug seacocks, 566–67 rubber sanitation hoses, 535 rubber sleeve bearings, 422–23, 424, 449–51 rudder bearings, 631–33 rudderhead fittings, 635–36, 640 rudders: auxiliary, 655, 656; construction, 630–31; installation, 620–21; maintenance and troubleshooting, 630–31; twin installation, 628–30, 629; wide-angle geometry, 637–38 rudder shaft seals, 449, 584, 634–35 rudderstocks, 623, 630–31, 632, 634–35 rudderstops, 645–46 Rule Industries, 580 Rule pumps, 603, 605 S sacrificial anodes. See zinc anodes SAE (Society of Automotive Engineers), 164, 166 sailboats: antennas, 345–46; lightning protection, 222–23, 232; stainless steel corrosion, 204; struts, 449 saildrives, 424, 428 sail locker, 710 sails. See headsails; mainsails sail tracks and slides, 743 saltwater intrusion, 360–61 Sanden clutch, 500, 501–4 Sanden compressors, 501–4 sanitation hoses, 535–36, 542 sanitation systems, 516–17, 535–36, 541, 542, 544, 558–60, 559 SanX MSD (Sealand), 560 scarf joints, 732, 737 Schaefer in-boom reefing, 781 Schrader-type valves, 506, 511–14 scientific rig tensioning, 763–64 sealed valve regulated (SVR) batteries. See gel-cell batteries. SCR (silicon-controlled rectifier), 86–87, 88, 238, 240 seacocks, 560–69; ABYC standards, 560–61, 564; galvanic isolation, 207; handles, 561, 562; installation, 490–91, 567–69; ISO standards, 561, 564; maintenance, 532; materials, 562–64, 567–68; resistance, 578; testing, 564–65, 568; types of, 561, 562, 565–67 Sea Frost holding plate, 477 SeaLand SanX MSD, 560 sealed combustion chamber, 686 Sea Recovery Energy Transfer Device, 609–11 self-aligning bearings, 632 self-steering. See wind vane self-steering self-tailing winches, 703–4, 708 series regulators, 40, 41, 45 series-wound motors, 306–7, 308–9, 311, 314–15 servopendulum wind vane self-steering, 654, 655, 656 setscrew, 437, 438 shaded-pole induction motors, 308 shaft brakes, 435–37 shaft log, 446, 447, 449 shaft seals: ABYC standards, 442, 443; carbonceramic seals, 575; engine alignment and, 448–49; externally driven compressors, 495, 496; leaks, 584; lip-type seals, 424, 447–48, 449, 575, 588, 589, 634, 635; mechanical seals, 445–47, 446, 449; replacement, 588–89; rudder shaft seals, 449, 584, 634–35; stuffing boxes, 422–23, 424, 442–45, 449, 633, 634 sheaves, 627, 638–39 shedding (battery failure), 8–9, 19 shielding techniques, 356 INDEX 815ship-to-shore transfer switch
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