Six Considerations for Connectors Used in Marine Applications
Watercraft engineers must heed the American Boat and Yacht Council standards. Beyond these basics, keep six directives in mind to design reliable connected systems for even the roughest of waters.
By Rob Iversrud, Product and Category Manager, Waytek
Electrical connectors used in boats and other marine applications must meet exacting standards, especially when it comes to withstanding the effects of weather, water and saltwater, vibration, and temperature extremes. In addition, limited space is often a factor, calling for compact connectors or connectors with high pin counts to handle multiple wires.
The American Boat and Yacht Council (ABYC) maintains comprehensive standards for direct current electrical systems on boats. Within these standards are several connector-specific directives that can serve as a framework for understanding connector selection requirements.
1) Weatherproof and/or waterproof design
The ABYC stipulates that plugs and receptacles exposed to weather must be weatherproof and, if subject to immersion, watertight. Before purchasing a connector, check to see its Ingress Protection rating and make sure that it is capable of long-term performance under the intended conditions.
2) Non-interchangeability
Per ABYC, receptacles and matching plugs used on DC systems must not be interchangeable with receptacles and matching plugs used elsewhere on the boat for AC systems.
One way to prevent improper crossing of systems and connections is the use of color-coded wiring, a well-established practice in the marine industry. The ABYC provides extensive wire color-coding charts for guidance. In addition, some manufacturers provide connectors in multiple color options to support color-coding.
3) Limited flexing
The ABYC states that plugs and receptacles must incorporate means for supporting all wires to limit flexing at the connection. Today’s leading connector manufacturers provide models with built-in strain relief in the form of extended housing to prevent wire bending.
4) Disengagement Force
Per ABYC, plug connectors shall have a minimum disengagement force of six pounds along the axial direction of the connector for one minute. This requirement is easily met and exceeded by many heavy-duty connectors in the marketplace.
Connectors with self-closing snap-style covers or connector position assurance (CPA) mechanisms typically ensure the minimum engagement required to keep connectors from accidentally disengaging in marine applications.
5) Capacity
The ABYC states that the connector’s capacity shall be selected to meet or exceed the ampacity and temperature rating of the connecting conductors in addition to its wire size capability.
Make sure your connectors are rated to handle the current of the boat’s electrical system and the temperature of the operating environment. If current exceeds the connector’s capacity, it can increase resistance, cause component wear and tear, and lead to voltage drops, system malfunctions, or failures.
6) Short circuit protection
Per the ABYC, each terminal in a multi-wire plug and receptacle shall be protected from accidental short-circuiting to adjacent terminals. Today’s industry-standard multi-pin connectors are manufactured to maintain adequate separation of terminals inside the housing.
Meeting the Marine Challenge
The ABYC’s specifications set the bar high for connector systems used in marine applications. Fortunately, connectors that meet or exceed these standards are widely available. In addition to the connectors mentioned above, other reliable options include heavy-duty connectors in the ATP Series and ATM Series by Amphenol Sine Systems, Weather-Pack and Metri-Pack connectors from Aptiv, and MX150 connectors from Molex.
Connectors used in marine applications will typically have high IP ratings and operating temperature ranges, and will be constructed to handle shock, vibration, and exposure to corrosive chemicals and environmental conditions. Many of the connectors that are used for marine applications are also ideal for other demanding segments such as heavy-duty construction vehicles, off-road vehicles, and agricultural equipment. For more information, see the ABYC’s standards for DC wiring, review IP ratings for electrical components, and consult manufacturer specifications before purchasing connectors for marine use.
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