Make Your Marine Electrical Connectors Waterproof
Keeping your boat’s electrical system connected properly is key to maintaining safe and efficient operation. That means avoiding the pitfalls of corrosion and water infiltration.
Luckily, there are plenty of options to protect your connections. Whether you’re dealing with harsh outdoor or marine environment electronics, hermetic waterproof connectors help safeguard against corrosion and moisture ingress.
Sealing
A corroded connection on a marine electrical wire can mean disaster. Keeping a supply of terminal connectors, extra wiring and a good quality crimp tool on board can help save you some major heartache in case an issue arises at sea.
Marine grade electrical connectors are made of heavy-duty tinned copper, which is more resistant to corrosion than untinned versions. They are typically sealed in plastic and feature closed front lugs to prevent water intrusion. They are designed to be crimped, which provides a secure mechanical connection that can withstand the tension and flexing of wires in a boat.
Heat shrink tubing is a marine electrical connectors waterproof great way to cover a crimped connection and keep salt, oil, moisture, contaminants, and dirt from reaching the conductors inside the lug. The epoxy-lined heat shrink is easy to apply, and it creates an environmental seal that protects the lug from the elements.
It’s also wise to leave some wire slack, which reduces the chance of strain on the connections and can help avoid movement in the area. The little steps you take to waterproof your electrical connectors today will pay off in a safer, more reliable and efficient system tomorrow. The right products and tools make all the difference. Pacer offers a wide range of electrical wire connectors and kits to meet your every need.
Insulation
Keeping water out of electrical wiring is vital to safety and reliability. Unless the connections are waterproof, they can easily corrode, and a bad connection can incapacitate your engine or cause a fire.
If you’re unsure whether your wires are waterproof, strip some of the insulating jacket away and inspect it for corrosion. Ideally, all exposed copper will be silvery or pinkish; if it’s blackened, that’s an indication that the copper is corroding. Inspect all exposed conductors and replace any that are corroded.
Another way to make sure your electrical connections are waterproof is to use marine grade terminals, lugs and connectors. These are typically made from tinned copper to resist the effects of salt and moisture. Also, they feature closed front lugs to further protect the conductors from water intrusion.
When crimping terminals, always crimp first and then solder. This complies with ABYC guidelines for making electrical connections, and it’s the best way to ensure a mechanically solid connection. Avoid relying solely on soldering; it’s easy to make a poor solder joint that won’t be durable in a marine environment.
You can also seal electrical connections with heat-shrink tubing. It’s available in a variety of sizes, so choose one that fits the lugs and connectors you need waterproof connector manufacturer to seal. These tubings have a liner that melts and bonds to the insulation when heated, so they create a waterproof (or nearly waterproof) sheath around the connection.
Heat Shrink
Heat shrink marine electrical connectors are a form of tubing designed to join wire connections and provide insulation. They typically feature a dual wall design with an inner layer that will melt into place when heated, creating a strong and secure seal that is resistant to moisture and corrosion.
The outer shell of the tube can be made from a wide range of materials including polyolefin, polyvinyl chloride (PVC), Viton(r) for high-temperature and corrosive applications, Neoprene(r) and fluorinated ethylene propylene (FEP). A common material is cross-linked polyolefin that provides great tensile strength while being waterproof and oil-resistant.
Most heat shrink tubing has a 3:1 shrink ratio, meaning it will shrink to one-third its original diameter once heated. It’s available in different colours to allow for easy identification of components and features an adhesive lining that will flow and bond with the surface of the underlying cable or connector, forming a protective barrier that is impervious to water and dust.
These durable tubing marine electrical connectors can be crimped in the field to ensure strong and reliable connections. This is preferable to using a soldering iron, which may cause corrosion and shorts in the bilge due to poor crimps. While liquid electrical tape is quick and convenient, it’s not as robust as heat-shrink tubing and shouldn’t be used for a permanent marine wire connection.
Butt Splice
Butt splice connectors are one of the most useful tools in your marine electrical wiring kit. Also known as a barrel splice, this device allows an electrical current to pass safely from one wire end-to-end. It can accommodate both stranded and solid conductors of various sizes, including 14 and 16AWG. It is ideal for extending and joining a cable, as well as terminating or repairing existing ones.
The insulated part of the butt splice connects the two ends of the cable together. It consists of a crimp-style sleeve that contains a conductive interior. You must first strip the ends of your wires and then insert them into the sleeve, where they will be crimped. You can use a pair of crimping pliers for this purpose. After crimping, you must heat the butt splice to activate its epoxy lining. The butt splice connector is available in various materials, such as vinyl, nylon, and non-insulated, depending on your installation requirements.
While butt splice connectors are useful for marine electrical wiring, there are also several different types of wire connectors that you can use in other applications as well. Some are more efficient than others, and you should choose the type that best suits your project. The factors that you should consider include the insulation, sleeve material, and diameter. You should also check if the connectors are waterproof, as this will help to protect your wiring from moisture and other environmental hazards.