A few days ago I was moving "Pleiades" to Saul Junction in the gathering dusk (we had a timber delivery the next day, so looking for a lorry friendly mooring). As I was reversing towards a suitable mooring space, suddenly all the lights went out, and as she is diesel/electric drive and I was making the short journey on battery power only, I lost propulsion as well. Fortunately the wind had fallen to a gentle breeze so I managed to go below and restore power by switching the battery off and on a few times, before we hit anything.
The switch is a BEP Marine item, rated at 600 amps. Contacts are a copper/brass plate rotating over a pair of electroplated copper bolts. Not very sophisticated.
Later investigation showed that the contacts were badly burnt and eroded.

I initially suspected that the culprit was the propulsion motor speed controllers, as these contain several large capacitors that charge up quite abruptly when a battery is first connected, giving a big and noisy spark. However I have a contactor (big relay) fitted, with a 470 ohm 2W resistor bypassing its contacts, which is supposed to charge the capacitors slowly enough to avoid the big spark. To test if this was the cause I disconnected the motor circuit completely, leaving the rest of the boats systems as normal. Reconnecting the battery still generated the big spark. Further elimination showed this to be down to the inverter/chargers.
Oh ho! Suddenly, this appears to be not just a problem with my system, but potentially for any one which has similar equipment.
I have two Victron combi inverter chargers, model 48-3000-35. I'm guessing they also contain capacitors sufficient to cause significant arcing when the battery switch is turned on. I don't know if the problem is worse as these are 48 Volt items. I do know that battery switch failure is not uncommon.
My proposed solution is to do something similar to the motor circuit. I propose to put a 470 ohm 6W power resistor in series with a push button switch across the battery switch so that pushing the button for 20 seconds or so will bypass the battery switch and pre-charge everything before turning on the main switch.
Will this solve the problem? Anything I'm missing? Over to the experts!
Rick




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