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A different Wiring Job

Old 03-16-2016, 04:54 AM
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Default A different Wiring Job

I thought some of the THT crowd might like to see a little different approach to wiring. This is what we do in the racing world. My company designs and builds custom wiring systems in conjunction with data and ecu system design.

These are some shots of a project we just wrapped up for a customer. The main loom is a power and signal loom using a Motec CDL3 dash display and a PDM15 power controller. In racing we have gotten 100% away from relays and breakers, and now use power controllers for almost everything. The PDM15 is a 15 channel output ( 8X20A and 8X8A) and 15 input device that you can program with current load trips and failover logic. It also transmits its status for all channels to the dash over CAN (same protocol as NMEA2000) so we have logged memory of every current draw and every switch position. The switches you see just carry a low side signal to the PDM to tell it if the switch is on or not. No current is carried by the switch.

The only thing that's missing from this shot is the ECU and engine loom which were already installed in the car.

The loom itself took about 35 hours to build and another 6 or so to design in CAD. It has over 1200' of wire in it (lots of 24 and 26 AWG for signals). The whole package weighed in at a hair over 6 lbs.


Last edited by CMS_Sprint; 03-16-2016 at 08:43 AM.
Old 03-16-2016, 06:12 AM
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Sounds interesting, but the picture isn't working.
Old 03-16-2016, 08:45 AM
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Originally Posted by davidwademarine View Post
Sounds interesting, but the picture isn't working.
Should be visible now? Let me know if not..

Thanks!
Old 03-16-2016, 10:34 AM
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That's very cool. It seems similar to the BEP CZone system. Like LiFePO4 battery technology, I think it's a great idea but today's pricing makes it difficult to justify for a plain ol' boat.
Old 03-16-2016, 10:35 AM
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Nice work. It's just a matter of time before boats go this direction. Far safer and more reliable.
Had a customer who wanted a radar detector in his new Buick wired so it was on with the ignition. Seemed a simple enough request (from his point of view), but he just couldn't grasp that there are virtually no places to find that power source in a new car these days.
Old 03-16-2016, 10:41 AM
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Originally Posted by loose_cannon View Post
Nice work. It's just a matter of time before boats go this direction. Far safer and more reliable.
Had a customer who wanted a radar detector in his new Buick wired so it was on with the ignition. Seemed a simple enough request (from his point of view), but he just couldn't grasp that there are virtually no places to find that power source in a new car these days.
The rear view mirror?
Old 03-16-2016, 10:43 AM
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If boat mfg's used a standard between all I can see this saving money on new boats.

To retrofit, this would be impractical as you need to pull the loom all over the place to connect devices.

Still, pretty cool stuff.
Old 03-16-2016, 11:28 AM
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This is a very interesting product. Raymarine has been working on some digital switching that interfaces with their chartplotters, as well. This should be the new "standard", as the "old reliable" way of wiring is just getting old...
Old 03-16-2016, 01:09 PM
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Now don't come on here with some new fangled way of wiring for boats that is neat, clean, and easy to use! There is nothing wrong with wires that have crappy scotch locks for joining wires, or non-heat shrink butt connectors that corrode, fall apart and provide a less than optimum current load. Why, if you take away the hours of fun tracing down shorts and ground faults, what the heck is there left to do with a boat?!?!
Old 03-16-2016, 01:13 PM
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Looks cool for a car or a race car. 1200 feet of wire in a set of looms that short?

The only type of boats where I can see this working is small low cost production boats. The bigger the boat is, the more complex the wiring system that is needed. Even 25 ft boats can have very complex electrical system requirements. Every owner has different needs so the wiring will always be different. Nothing cookie cutter in boats.
Old 03-16-2016, 01:37 PM
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this is great for newer ecu driven diesel engines
Old 03-16-2016, 05:23 PM
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Ever see what Viking does ?
Old 03-16-2016, 05:31 PM
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Originally Posted by saltwaters View Post
Looks cool for a car or a race car. 1200 feet of wire in a set of looms that short?

The only type of boats where I can see this working is small low cost production boats. The bigger the boat is, the more complex the wiring system that is needed. Even 25 ft boats can have very complex electrical system requirements. Every owner has different needs so the wiring will always be different. Nothing cookie cutter in boats.
That's interesting as I see it completely differently. I think cars are much more different. On a boat, single main run to the helm, split off to basics there:
Stereo
VHF
Radar
Plotter(s)
Auxiliary
Switches
Nav lights
Courtesy lights
Extras
This is just for non-engine items. Engine manufacturers have their own runs for them and gauges. It would be really nice to have pre-riggers for all of the helm items when re-wiring a boat. I'm in the process of that now and whether I have to pull single strands or a a full rig makes no difference to me except I would only have to pull everything once. Would probably need bare wire ends still or special crimp on plugs for the accessories. Reasonably priced package would save its extra cost in time saved.

To the original poster, if you want a Guinea pig feel free to contact me! ��
Old 03-16-2016, 05:42 PM
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I would hate to accidently run a screw in it. It would take out the entire system.
Old 03-16-2016, 06:49 PM
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Originally Posted by ReelPlumber View Post
I would hate to accidently run a screw in it. It would take out the entire system.
True. If that Motec device fails, it could easily disable 15 other devices. That may be a minor inconvenience for some boaters, but it could be a huge issue for other folks. Luckily for me, those devices are so expensive that I won't need to worry about their failure modes for a long time.
Old 03-17-2016, 09:17 AM
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can you make one for this .......lol

er over 7 km klicks in this 65 footer

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Old 03-20-2016, 06:51 AM
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Originally Posted by wildthing View Post
can you make one for this .......lol

er over 7 km klicks in this 65 footer
No thanks...The most complex loom we've ever built was a 1 miler (5265 feet to be exact)...That's plenty!

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