Jeff Kotz
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Marine electrical systems expert and founder of Pacific Yacht Systems
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Claims by Jeff Kotz (20 of 31)
Inverter chargers are dangerous devices because they can draw large DC currents (up to 300-400 amps) and large AC input currents (up to 30-50 amps), making them the second-most power-hungry device on a boat after thrusters; continuous operation for extended periods requires robust protection.
An alternator must be directly connected to the battery via an unswitched fused line to prevent damage from switching it off while running; the original story of Kotz's blown alternator in 2006 illustrates why this is critical—turning off the battery switch while the engine runs and the alternator is generating can destroy the alternator.
When a battery combiner fuse blows silently, the house battery becomes permanently disconnected without alarm or warning, remaining depleted until discovered days or months later; a completely discharged thruster battery or critical backup battery left in this state creates a major safety issue.
A hot water heater must never run off an inverter, because even the largest battery banks (including lithium) cannot supply the continuous high current draw required for water heating; attempting to do so is equivalent to 'burning bills' and will deplete batteries in approximately 2 hours.
The principle of 'unswitched versus switched distribution' is a critical foundational concept in marine electrical design that is widely ignored by boat owners and installers, and ignoring it leads to unpredictable system failures described as 'magic' (unintended mysterious behavior).
Unswitched distribution includes all power generation and battery charging sources (chargers, alternators, solar controllers, battery isolators, battery combiners, wind turbines, methanol fuel cells, bilge pumps, CO2 systems) and must all be fused but remain connected before the main battery switch.
If a battery charger is connected to the switched side of the circuit (downstream of the battery switch) rather than the unswitched side (upstream), turning off the battery switch will disconnect the charger from the batteries while leaving it connected to the loads via the panel, creating dangerous 'magic' where loads receive power despite the battery being nominally disconnected.
An AC system diagram on a boat, regardless of boat size (from 20 feet to 150+ feet), follows the same conceptual structure: AC panel with non-inverter loads (hot water, battery charger) connected to one circuit, and inverter circuits (AC pass-through or inverter load) for devices like microwave, fridge, and AC outlets connected to another circuit.
The frequency of battery recharging opportunities (e.g., anchoring for 3 days without engine use vs. daily generator operation) dramatically affects the type and size of electrical system required; boats without frequent recharging need larger batteries or generation capacity than boats with daily charging access.
Firefly AGM batteries offer 4 times the cycle life of flooded lead-acid batteries, 65% usable capacity (compared to lower depth-of-discharge limits on other lead-acid types), and approximately 3,600 cycles at 50% depth of discharge—equivalent to a lifespan of ~1,500 years if used on a typical boat.
Batteries must be charged at a minimum rate of 10% of battery capacity (e.g., 60 amps for a 600 amp-hour battery bank); charging at less than this rate causes premature battery capacity loss and significantly shortened lifespan, even though slower charging is physically possible.
When upgrading a boat's alternator from 55 amps to 160 amps, the wire between the alternator and the battery must also be upgraded; using the original small-gauge wire (often 10 gauge, rated for ~30 amps) as a bottleneck limits the alternator output and risks melting the wire insulation.
Rule #1 in marine electrical: 'Nothing is ever easy.' Changing any one component (alternator, charger, solar panel) requires verifying that related components (wiring, fuses, controllers) are appropriately sized for the new load, because interactions between components are extensive and often invisible.
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