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posted to rec.boats.electronics
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I posted this on another bulletin where a contributor had bonded all
his underwater metal with 1" copper straps and needed to test. Copied here for anyone having electrolysis problems. An ohm meter is a poor way to check bonding connections. I use a 12 volt lamp and make a probe using a screwdriver. Hook a long enough wire to the positive terminal of the starting battery and then poke the screwdriver into each of the through hull fittings and make sure the lamp lights. An ohm meter is only testing the circuit at micro- amps. The following applies mainly to boats left in the water. Trailered boats rarely spend enough time in the water for electrolysis to be a problem. ELECTROLYSIS 101. I've worked with electrolysis for 18 years including live-aboard on a steel yacht for 14. We have sold thousands of our galvanic isolators and handle numerous emails/phone calls daily on electrolysis situations. BONDING STRAPS Although your copper straps look impressive they are totally unnecessary. The wire at the most only carries a few milliamps and there is no concern for voltage drop so the copper only needs to be heavy enough to resist deterioration from oxidation. A 10 gauge copper wire is more than adequate. I use non stranded 10 gauge bare copper wire for my installations, being careful to secure it so it is not subject to flexing from boat motion. Non stranded wire has much less surface area and avoids the cavities between the strands where moisture and corrosion/oxidation can progress. THEORY Electrolysis only happens when two dissimilar metals are immersed in an electrolyte and connected together. The dissimilar metals have different electrolysis voltages so if you connect them together current flows through the connecting wire one direction and through the water the other. As the current leaves one metal to travel to the other, it causes metal to come off one surface and be deposited on the other like battery plates so the higher voltage metal suffers electrolysis. Electrolysis can also occur when an adjacent structure or boat is injecting DC current into the water and that current goes in one end of your boat and out the other on its way to the destination. This can cause electrolysis even though your boat is not an offender. PROTECTION There are basically 2 ways to reduce electrolysis. The PREFERABLE one is to DISCONNECT the electrical circuit. If this can't be done, the second method is to provide a sacrificial anode (Zinc) so it deteriorates rather than your expensive equipment. a) DISCONNECTING Electrolysis cannot occur on an isolated piece of metal in salt water. It is all at the same voltage but if it is isolated no current can flow so there is no electrolysis. When it is connected to another piece of metal, ESPECIALLY if the other piece is a different metal, you just created a shorted battery and electrolysis will start. By following the wrong advise and bonding everything in the boat you are creating batteries where it is unnecessary and making electrolysis problems worse. ANN-MARIE'S RULE #1. Only bond underwater items that are showing symptoms of electrolysis. If it ain't broke, DON'T fix it. Once you bond it unnecessarily you have CREATED the circuit rather than DISCONNECTING it. You are now stuck with providing Zincs since you have removed the first line of protection. Although some through hulls appear to be isolated due to sitting in fiberglass and using non-metallic tubing, they quite often are not and WILL need bonding. For example the raw water cooling inlet for an inboard engine is in fact connected to the engine block by the salt water in the tubing and may need bonding so the current flows though copper rather than the water and in/out of the through hull. b) SACRIFICIAL ZINC There are situations where different metals cannot be disconnected and you are stuck with putting zincs on them to provided a target for the electrolysis. Zincs have a higher electrolytic voltage than marine metals so it is the first to deteriorate. Keep in mind that the zinc will CREATE electrolysis (favorable electrolysis since the zinc is being eaten up). Putting zincs where they were not needed will still cause the zincs to erode away since they create the battery situation where none may have existed. The range of protection a zinc can supply to other metals bonded to it is limited by the conductivity of the water. In salt water you get coverage for a radius of about 4 to 6 feet. A zinc on the stern of a 14 ft boat where everything is bonded is only protecting half the boat. This range gets even less in fresh water and may reduce to only inches. Often magnesium is substituted for zinc in fresh water to provide an even higher voltage to push through the fresh water. USE A CONDOM Over 90% of our customers electrolysis problems are created by the shore power connection. You could theoretically disconnect the ground connection in the shore power and avoid electrolysis (and in some cases this is a solution) but ABYC regulations require the AC ground be connected to the DC ground so an electrical fault on the boat won't electrocute swimmers in the vicinity. When you connect your underwater metal to the shore power ground you have "bonded" with every other boat on the docks who have the same connection. Now electrolysis currents are free to flow anywhere in the marina and it only takes one boat with a 12 volt DC leakage to eat up every boat within a wide radius even though the offender has zero electrolysis evidence. Your protection is a Galvanic Isolator in the ground connection of the shore power lead. You don't have to purchase ours (although they are typically less than 1/2 the price of our competitors). Any Galvanic Isolator that meets AYBC specifications will do - they are not rocket science and extremely reliable. We have sold thousands, all on unconditional warranty and have never had a return due to failure. Feel free to ask general interest questions here or email me if you prefer. |
#3
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posted to rec.boats.electronics
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On Sun, 6 Jan 2008 08:12:46 -0800 (PST), Andina Marie
wrote: On Jan 6, 6:06 am, "Steve Lusardi" wrote: Andina, I found your synopsis of this issue very good. This problem is not understood by most people. Please explain what a Galvanic Isolator is. I find absolutely no reason to connect shore earth to your boat, ever. There should be a ships earth and it should never be the hull, either on the AC side or the DC side. The ships earth should be isolated from the hull. There should be an LED mounted in an obvious location connected between the hull and ships earth. Normally this LED would be off, unless there is a DC leak to the hull. This would then allow the LED to turn on and alert the crew to locate the fault immediately. On the AC side, an isolation transformer is a necessity. The ships safety earth is then bonded to neutral at the panel only and the main ships ckt breaker should be of the GFI type. Steve REPLY from ANDINA. A Galvanic isolator consists of back to back diodes which still provide an electrical path for AC current but block DC voltages up to about 1 volt. So the ground protection for electrical faults is retained but the small DC voltages that cause electrolysis are blocked. ABYC specifications require that the Galvanic Isolator be able to carry 130% of rated current continuously. This is required because if an appliance on a boat was wired incorrectly and using the ground instead of the neutral, the total current would be flowing through the isolator. Should the isolator then fail under load, the AC would now be connected directly to the ground that has become disconnected from the shore ground. This puts 120 volts AC on all the underwater items on your boat which can KILL SWIMMERS IN THE VICINITY. Your statement that:- I find absolutely no reason to connect shore earth to your boat, ever. is very dangerous without explanation. Omitting this connection can kill people. On most boats you cannot isolate the DC ground from the underwater metal because the starter motor is bolted to the engine block which in turn connects to the propeller shaft and the water. So without the ground, an internal failure of the battery charger could put 120 or 230 volts AC on your DC ground and into the water. Relying on indicators or alarms is not a satisfactory solution, it only takes milliseconds to kill someone. Relying on a GFI Circuit breaker is not satisfactory. In salt water the current flowing though a GFIC can kill a swimmer before the GFIC can trip. Now I agree that the probability of these worst case scenarios is remote, however the consequences are grim. The ABYC specifications err on the conservative side to avoid leaving the risk/consequence decision up to the boat owner. If using an isolation transformer the risk is miniscule. Isolation transformers are extremely reliable, the only risk would be an uninformed installer making an error in wiring up equipment. Without the isolation transformer and with no ground you are betting the reliability of your equipment against the life of swimmers in the vicinity of your boat. Good advice. Bottom line: unless an isolation transformer is (properly) installed, the shore power green grounding wire should ALWAYS be connected to the boat's AC ground, preferrably through a galvanic isolator. Chuck ----== Posted via Newsfeeds.Com - Unlimited-Unrestricted-Secure Usenet News==---- http://www.newsfeeds.com The #1 Newsgroup Service in the World! 120,000+ Newsgroups ----= East and West-Coast Server Farms - Total Privacy via Encryption =---- |
#4
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posted to rec.boats.electronics
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Andina Marie wrote in news:8810ac1d-6d25-48fb-b03f-
: A Galvanic isolator consists of back to back diodes which still provide an electrical path for AC current but block DC voltages up to about 1 volt. So the ground protection for electrical faults is retained but the small DC voltages that cause electrolysis are blocked. Assuming, of course, that nothing in the boat hooked to the AC line, like AC compressors, fan motors, battery chargers, AC-powered refridgeration and lighting has absolute NO LEAKAGE that will forward bias any of those diodes. This dirty little secret has trashed many boats I know of with diode galvanic isolators. Even the slightest AC leakage, not even enough to trip a good GFCI, forward biases the diodes in both directions 60 times a second, allowing galvanic current to flow through the forward biased diodes during every AC peak in the same direction.....completely negating the flow-stop protection the diodes were supposed to provide. Almost ANY motor sitting for years in the marine seawater environment has some small leakage, more than enough to forward bias galvanic isolator diodes without causing any noticable GFCI trips or any kind of shocking experience because of the working circuit grounds. The DC galvanic current flows right along with the leakage current to marina grounds and to the other boats, completing the circuits. The cure isn't cheap....but is cheaper than new propulsion, rudders, posts, shafts, through hull fittings and labor...ISOLATION TRANSFORMERS to take the boat completely out of the AC line loop. Now only magnetically coupled to the power grid, the boat IS isolated....but not cheaply with high profit diodes. http://www.charlesindustries.com/main/iso_guard.html http://www.defender.com/product.jsp?path=-1|328|303336&id=614209 $567 (120/240VAC 30A) http://tinyurl.com/yus7an (West Marine but probably only 120VAC) $495 30A of isolated AC certified for boats. How much is a new shaft and screw, installed? It's a fair trade.... Shhhh.....don't tell anyone....You can also use it to boost 120VAC to 120VAC/240VAC to run the European equipment the boat came with!.....shhhh. Did I say that? Shhhh....you can also use it to run 120VAC outlets off 240VAC supplies outside the USA, too, if you use the 120/240 models. They make great boost drop transformers, properly breakered in/out. Larry -- As the price of Monopoly money rises, at some point it will equal Federal Reserve Private Bank fake banknotes in value! |
#5
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posted to rec.boats.electronics
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Larry is correct. If you have an older boat that has accumulated fine
salt deposits over the years, AC leakage to ground can diminish the effectiveness of Galvanic Isolators. You can test very easily after installing the galvanic isolator. If the AC voltage you read across it is more than about 0.3 volts you are starting to lose isolation. Typically the worst case loss is only up to about 50% as the DC rides through on one of the AC polarities when the diodes go into conduction. On the other polarity of the AC it is bucking the DC. You can solve this problem with a Galvanic Capacitor. It is just a large capacitor that you put in parallel with the Galvanic Isolator so the AC goes through it instead of the isolator. Some manufacturers include a capacitor in the isolator but so far as I can see, not a single manufacturer will tell you the capacity of it and since the space occupied in their isolators is inadequate I feel sure they are just putting in a small token capacitor so they can say it is there. Our isolators have no capacitor. If you find you need one, we sell a Galvanic Capacitor that is rated for 5 amps AC continuous that you connect in parallel with the isolator. This would permit up to 5 amps ground leakage before it compromises the galvanic isolator efficiency. |
#6
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posted to rec.boats.electronics
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On Mon, 7 Jan 2008 06:49:19 -0800 (PST), Andina Marie
wrote: snip Our isolators have no capacitor. If you find you need one, we sell a Galvanic Capacitor that is rated for 5 amps AC continuous that you connect in parallel with the isolator. This would permit up to 5 amps ground leakage before it compromises the galvanic isolator efficiency. With 5 amps of leakage current, there is a serious problem that ought to be fixed aside from any compromising effect on galvanic isolation. Sounds like an electrocution waiting to happen. All it takes is a corroded (or non-existing) grounding connection to the cabinet of a refrigerator. However, a functioning GFCI will trip immediately with 5 amps of leakage through the green grounding conductor. Most will trip with a thousandth of that current (5-6 mA). Chuck ----== Posted via Newsfeeds.Com - Unlimited-Unrestricted-Secure Usenet News==---- http://www.newsfeeds.com The #1 Newsgroup Service in the World! 120,000+ Newsgroups ----= East and West-Coast Server Farms - Total Privacy via Encryption =---- |
#7
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posted to rec.boats.electronics
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You are correct Larry. I designed my own isolation transformer, because I
couldn't find one that met all my needs, but even building it myslf was not inexpensive. My xformer is capable of both 50 and 60 Hz, is capable of handling input power from 100 to 280 Volts. Input is phase and neutral, no safety earth. The output has 5 voltage steps manually selectable. The output winding is 230 volts with a center tapped neutral. Neutral is then tied to ships earth along with both generator neutrals. Its rating is 10 KW. My biggest problem was inrush current. This was resolved by employing a 300 W, 220 V light bulb in series with the primary and a 100 amp shunt around the lamp. This works perfectly where the user starts the xformer with the shunt disconnected and after secondary voltage is detected then engaging the shunt. Primary idle current, with no secondary load and without ferro resonant caps on the primary is .3 amps with 230 Volt input, so it is very efficient. The xformer case measures 25" W, 15" H and 17" D and it weighs 94 Kgs. This size was necessary because the galley and hot water is all electric. I carry only diesel fuel for safety reasons. I have to repeat myself here. There is absolutely no way to protect your hull from other boater's electrical faults if you connect shore safety earth to your boat. Of course there are safety risks, but they can be mitigated. Here is an interesting note. I designed two Isolation Transformers, this 10 KW model and an automatic 5 KW model. They were shown at the London Boat Show a few years back. I received "0" interest. People will not invest a dime to correct a problem they do not understand. Stupidity has its just rewards. Steve "Larry" wrote in message ... Andina Marie wrote in news:8810ac1d-6d25-48fb-b03f- : A Galvanic isolator consists of back to back diodes which still provide an electrical path for AC current but block DC voltages up to about 1 volt. So the ground protection for electrical faults is retained but the small DC voltages that cause electrolysis are blocked. Assuming, of course, that nothing in the boat hooked to the AC line, like AC compressors, fan motors, battery chargers, AC-powered refridgeration and lighting has absolute NO LEAKAGE that will forward bias any of those diodes. This dirty little secret has trashed many boats I know of with diode galvanic isolators. Even the slightest AC leakage, not even enough to trip a good GFCI, forward biases the diodes in both directions 60 times a second, allowing galvanic current to flow through the forward biased diodes during every AC peak in the same direction.....completely negating the flow-stop protection the diodes were supposed to provide. Almost ANY motor sitting for years in the marine seawater environment has some small leakage, more than enough to forward bias galvanic isolator diodes without causing any noticable GFCI trips or any kind of shocking experience because of the working circuit grounds. The DC galvanic current flows right along with the leakage current to marina grounds and to the other boats, completing the circuits. The cure isn't cheap....but is cheaper than new propulsion, rudders, posts, shafts, through hull fittings and labor...ISOLATION TRANSFORMERS to take the boat completely out of the AC line loop. Now only magnetically coupled to the power grid, the boat IS isolated....but not cheaply with high profit diodes. http://www.charlesindustries.com/main/iso_guard.html http://www.defender.com/product.jsp?path=-1|328|303336&id=614209 $567 (120/240VAC 30A) http://tinyurl.com/yus7an (West Marine but probably only 120VAC) $495 30A of isolated AC certified for boats. How much is a new shaft and screw, installed? It's a fair trade.... Shhhh.....don't tell anyone....You can also use it to boost 120VAC to 120VAC/240VAC to run the European equipment the boat came with!.....shhhh. Did I say that? Shhhh....you can also use it to run 120VAC outlets off 240VAC supplies outside the USA, too, if you use the 120/240 models. They make great boost drop transformers, properly breakered in/out. Larry -- As the price of Monopoly money rises, at some point it will equal Federal Reserve Private Bank fake banknotes in value! |
#8
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posted to rec.boats.electronics
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"Steve Lusardi" wrote in news:fma6k9$ijg$00$1
@news.t-online.com: People will not invest a dime to correct a problem they do not understand. Stupidity has its just rewards. Steve This is absolutely true. Trying to explain it to them only makes them angry. Unlike usenet, I keep it shut on the docks...(c; |
#9
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posted to rec.boats.electronics
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On Feb 2, 6:23*am, Larry wrote:
"Steve Lusardi" wrote in news:fma6k9$ijg$00$1 @news.t-online.com: People will not invest a dime to correct a problem they do not understand. Stupidity has its just rewards.. Steve This is absolutely true. *Trying to explain it to them only makes them angry. *Unlike usenet, I keep it shut on the docks...(c; Just a comment/question about GFCIs. The typical North American GFCI operates when there is an unbalance beteen the amount of AC flowing in the live and flowing in the neutral wire. That unbalance may be due a potentially dangerous leakage to ground (or in this case the boat/water) but not necessarily. That unbalance operation is the reason that GFCIs are not recommneded for use in domestic situations for fridges and freezers. You can come home to a fridge of bad food! Not that we should not use them and also understand how and why they operate to provide safety, but it's almost as if the designation 'Ground Fault Current ...... ' is a misnomer. In Europe and elswhere understand they are called RCDs. I liked the discussion about isolation transformers. What sort of wattage ratings would be typical; realizing that when the boat is at the wharf unused there may be a minimum load, due to a little bit of battery top up, maybe a fridge and a small bilge pump (itself often on 12 or 24 volt DC boat supply) that may cut in occasionally. Perhaps intermittently 500 watts????? We have on hand, for example several hefty transformers (basically one to one ratio, with a few extra volt taps) each capable of at least 250 watts or more. Have often considered using them as isolation and minor voltage adjustment devices. Also as mentioned, properly arranged, transformer/transformers can be used to 'match' land voltages of around 230v OR 115v to the boat. |
#10
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posted to rec.boats.electronics
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Terry,
Your questions are right on target. In Germany, the main breaker must be GFI. Therefore all loads within the distribution will be GF protected. In my experience, there are only two types in Europe a .030 Amp and a .3 Amp breaker. They do measure that load current matches return current. If there is an imbalance, then there must be another return path to safety earth. In Europe you will never see those in-line AC filters whose case is screwed to the equipment frame exactly for that reason, as they bleed to frame(safety earth). On a boat, they are very useful and if a more sensitive was available, I would use that. Isolation transformers can be made very elaborately or very inexpensively, depending on the application. Most importantly is the way you connect the safety earth wire from the shore outlet to your boat. I will not ever connect it, but to do that is illegal. If you must connect it, it must connect only to the transformer frame and NOT anywhere else. Your ship ground is from the centertap of the secondary winding. To determine how large the transformer should be, add all the loads that could be simultaneously connected and add 20%. Isolation transformer problems and there are a few. One, when connecting the boat to the shore connection and the transformer is larger than 1KW, you will very likely pop the ckt breaker for the feed because of inrush current. Two, efficiency can be a big issue, so electric use can be significantly higher. You cannot use an Auto Transformer for an isolation role. They are the typical step down transformers used to reduce 220 volt power for 110 volts loads. Another problem that I encountered is that the ones that I found were not suitable for marine use, even the ones so labeled. Problem solutions: In rush can be contained by using a common incandescent light bulb in series with the primary and after start, shorting past the lamp. Two, if idle current is higher than you wish, make the primary winding Ferro-resonant, by adding the appropriate capacitance in parallel with the winding. If you want to know how, contact me off-line and I will tell you. I decided to design and build my own, because I could not find one that met all my requirements. I am very happy to state that my transformer met all my requirements, is easy to use and very economical. My requirements: Accept input voltage between 100 Volts and 260 Volts (Japan = 100 V / UK = 260 Volts). Adjustable output voltage = (end of dock low voltage syndrome) Single phase only, output = 115 Volt secondary end to center tap and 230 Volt secondary end to end. Power needed = 10 KW Ferro Resonant primary selectable for both 50 Hz and 60 Hz. Steve "terry" wrote in message ... On Feb 2, 6:23 am, Larry wrote: "Steve Lusardi" wrote in news:fma6k9$ijg$00$1 @news.t-online.com: People will not invest a dime to correct a problem they do not understand. Stupidity has its just rewards. Steve This is absolutely true. Trying to explain it to them only makes them angry. Unlike usenet, I keep it shut on the docks...(c; Just a comment/question about GFCIs. The typical North American GFCI operates when there is an unbalance beteen the amount of AC flowing in the live and flowing in the neutral wire. That unbalance may be due a potentially dangerous leakage to ground (or in this case the boat/water) but not necessarily. That unbalance operation is the reason that GFCIs are not recommneded for use in domestic situations for fridges and freezers. You can come home to a fridge of bad food! Not that we should not use them and also understand how and why they operate to provide safety, but it's almost as if the designation 'Ground Fault Current ...... ' is a misnomer. In Europe and elswhere understand they are called RCDs. I liked the discussion about isolation transformers. What sort of wattage ratings would be typical; realizing that when the boat is at the wharf unused there may be a minimum load, due to a little bit of battery top up, maybe a fridge and a small bilge pump (itself often on 12 or 24 volt DC boat supply) that may cut in occasionally. Perhaps intermittently 500 watts????? We have on hand, for example several hefty transformers (basically one to one ratio, with a few extra volt taps) each capable of at least 250 watts or more. Have often considered using them as isolation and minor voltage adjustment devices. Also as mentioned, properly arranged, transformer/transformers can be used to 'match' land voltages of around 230v OR 115v to the boat. |
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