Kelley Hale

Energy Storage & Battery Management

The system uses a dual-battery configuration — a Victron AGM 12V starter battery and a Victron LiFePO4 12V 100Ah house battery. Battery management is handled by a VE.Bus BMS V2, with an Orion XS 12/12-50A DC-DC charger isolating and charging the starter battery from the house bank. A Victron SmartShunt/BMV-712 provides real-time battery monitoring.

AC System

Shore power enters through a 30A inlet and passes through a Victron isolation transformer for galvanic protection before reaching the main AC distribution panel. A Victron Multiplus inverter/charger handles both AC charging from shore power and DC-to-AC inversion when off-grid. The AC system includes GFCI outlets and reverse polarity protection with visual indication.

DC System & Distribution

A main DC distribution panel feeds two fused sub-panels supplying navigation lighting, cabin lighting with day/night control, bilge pump with automatic float switch and manual override plus alarm, windshield wiper, blower, VHF radio, USB charging, and a keyed ignition switch.

Renewable Energy & Victron Integration

A SunPower solar panel feeds a Victron MPPT charge controller, with the full Victron ecosystem integrated through a Cerbo GX with Touch 50 touchscreen display — providing unified monitoring of solar production, battery state, AC input/output, and all connected loads via Bluetooth and the VictronConnect app.

Navigation & Communications

A Garmin MFD is integrated via a NMEA 2000 backbone alongside a VHF radio with external speaker and antenna. Navigation lighting includes port, starboard, and stern lights with proper circuit protection.

Troubleshooting & Problem Solving

Three real-world faults were identified and resolved during the build. A reversed hot and neutral at the shore power inlet was immediately caught by the reverse polarity indicator and corrected. An external VHF speaker produced no output — tracing the issue revealed the speaker cable uses the outer sheath as the negative conductor, which required separating and terminating each conductor individually with heat-shrink butt splices. Solar data was absent from the Cerbo GX display because the MPPT's VE.Direct port had been used for a BMS charge-disconnect function; reconfiguring the MPPT to charge the AGM battery instead freed the port and restored full solar monitoring.

The Challenge

Boats connected to shore power are vulnerable to galvanic corrosion — stray currents flowing through the grounding conductor can slowly eat away at underwater metals. The owner needed an isolation transformer wired inline between the shore power inlet and the AC distribution panel to break that galvanic path while maintaining full electrical safety.

Mounting & Structural Considerations

At roughly 50 lbs, the Victron transformer needed a mounting location that could handle significant weight under dynamic sea conditions — heeling, wave impact, and vibration. We evaluated multiple locations in the stern cabin and selected a structurally sound bulkhead that allowed full backside access for through-bolting with appropriate backing hardware. This ensured a secure, permanent installation that could be inspected and serviced in the future.

Electrical Work

Routed and terminated all AC conductors with proper wire gauge selection based on circuit amperage and conductor length, in alignment with ABYC standards. Particular attention was given to the AC grounding conductor to ensure compliance with current-carrying and fault protection requirements. All conductors were installed with proper separation, strain relief, and chafe protection for clean, serviceable routing.

Configuration & Verification

Following installation, configured the system using the VictronConnect app, verifying correct operational settings and confirming the unit was properly integrated into the vessel's existing electrical system.

System Design

The electrical system includes an AGM starter battery, a bilge pump circuit, a fused distribution block, a Victron battery charger, and a dual-USB charging outlet. All components are being installed with careful attention to ABYC-aligned practices, including proper conductor sizing, circuit protection, and clean, serviceable routing.

Custom Panel Fabrication

A significant portion of the project has involved designing and fabricating custom console panels from marine-grade plywood to house the electrical controls. These panels were shaped and finished to complement the boat's woodwork, requiring careful consideration of both form and function. The goal is to create an installation that not only performs reliably but also visually integrates with the vessel's handcrafted aesthetic.

Expanding Scope

In addition to the electrical system, the project includes routing and installing a mechanical steering system and fuel distribution system, further contributing to the vessel's completion as a fully functional boat.

Key Takeaway

This project highlights the ability to execute clean, functional electrical installations while respecting and enhancing the visual integrity of a traditionally crafted vessel — where every wire run, every panel edge, and every fastener is part of the finished product.

DC System

Built around a dual-bank configuration (engine start and house), with 2 AWG marine-grade tinned copper primary cables and a 150A Class T fuse within 7 inches of the house battery positive terminal per ABYC E-11. The fused distribution panel supplies branch circuits for navigation lighting, cabin lighting, bilge pump with automatic float switch and manual override, windshield wiper, VHF radio, and USB charging — all sized to meet ABYC voltage drop requirements.

AC System

Fed via a 30A shore power inlet using 10/3 AWG marine-grade cable through a main breaker with reverse polarity indication. A ProSafe FS30 galvanic isolator is installed in the AC grounding conductor per ABYC A-28 to mitigate corrosion. A Guest ChargePro battery charger is integrated on a dedicated AC breaker, with system monitoring via Victron Bluetooth diagnostics.

Helm Panel Design

Designed the helm-facing layout with an emphasis on intuitive user interaction. Components are grouped by function using custom green faceplates — bilge pump controls on a single panel, cabin lighting with its switch, windshield wiper with its control. The goal was a clear, user-friendly interface where the relationship between switches and their loads is immediately apparent, even without labeling.

Standards Compliance

During the build, I identified and corrected an ABYC compliance oversight — conductors from the DC distribution panel to the navigation lighting overcurrent protection exceeded the 7-inch unsheathed limit. I retrofitted the installation with appropriate sheathing to bring the system into compliance. This correction reinforced the importance of continuous standards verification throughout the build process.