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Check your extension cords!

FSH 210 Sport

Jetboaters Fleet Admiral
Messages
7,968
Reaction score
9,894
Points
532
Location
Tranquility Base
Boat Make
Yamaha
Year
2020
Boat Model
FSH Sport
Boat Length
21
So today I charged up my batteries from yesterday’s outing.. a couple hours into recharging the 64Ah out of my trolling motor bank I open the Victron Energy app and check the chargers and the smart shut for the trolling motor battery bank. What I found didn’t make sense, the bulk charge only went to 49Ah’s, usually on a charge like that it would go all the way to 63Ah’s at least, and the now the absorption charge was happening with a voltage of 13.9 and 25A’s, hmmmm. Jump in the boat and look at the chargers their status lights look normal, then I feel the extension cord where it plugs in to the NOCO power port and its pretty warm, maybe even hot. I check the male end and its warm but not like the other end.

I grab another extension cord and plug it in.. the voltage on the chargers starts coming right up to their eventual 14.4 and shortly there after the amperage starts dropping off as it should. This different extension cord female plug gets a tiny bit warm but nothing like the other one. In the end, the absorption phase puts almost 14Ah’s into each battery, the usual amount is like .7 or point 7.

A close visual inspection of the female plug did not reveal anything obvious. So I did what I was taught and cut the ends off and prepped the cord for new plugs.

F3E26C51-C0B8-4745-9FA2-C9F62C104F74.jpeg

I would not have known anything was amiss unless I had the victron chargers and looked at the charge profile, something I regularly check when I check the smart shunt to make sure everything got charged up they way I was expecting. I use a #12 AWG extension cord which is rated for 20A’s and the draw was 11A’s.

One thing that I noticed that I don’t like about his extension cord is that there no AWG markings on the jacket of the cord, and when I stripped the outer casing back none of the internal wires are marked either. I used my strippers on the #12 setting and it stripped the wires correctly but I find that irregular that there was no wire size markings anywhere. Whereas the replacement cord I grabbed out of the shop was clearly marked on the jacket with the wire size and the temp rating which is important in determining the amperage rating of the wire. The ampacity of 12 AWG copper wire is typically rated between 20 to 30 amps, depending on the insulation type: 20 amps for 60°C insulation, 25 amps for 75°C insulation, and 30 amps for 90°C insulation.

Its a new season and we talk about what maintenance needs to be done so be sure and give your electrical cords a good visual inspection looking for discoloration in the jacket of the cord, and after your battery charger has been plugged in for a hour or so have a feel to see if there are any hot spots. If you find any irregularities in the plugs don’t just stop using them, cut the ends off so it will not get used again in that condition, any hot spots in the length of the cord, cut the ends off and throw the cord away. Just like a hammer with cracked handle, break it off so it cannot be used the risk isn’t worth it.


 
Last edited:
#12 is 20A max.
Ignore other ratings.
 
So today I charged up my batteries from yesterday’s outing.. a couple hours into recharging the 64Ah out of my trolling motor bank I open the Victron Energy app and check the chargers and the smart shut for the trolling motor battery bank. What I found didn’t make sense, the bulk charge only went to 49Ah’s, usually on a charge like that it would go all the way to 63Ah’s at least, and the now the absorption charge was happening with a voltage of 13.9 and 25A’s, hmmmm. Jump in the boat and look at the chargers their status lights look normal, then I feel the extension cord where it plugs in to the NOCO power port and its pretty warm, maybe even hot. I check the male end and it’s warm but not like the other end.

I grab another extension cord and plug it in.. the voltage on the chargers starts coming right up to their eventual 14.4 and shortly there after the amperage starts dropping off as it should. This different extension cord female plug gets a tiny bit warm but nothing like the other one. In the end, the absorption phase puts almost 14Ah’s into each battery, the usual amount is like .7 or point 7.

A close visual inspection of the female plug did not reveal anything obvious. So I did what I was taught and cut the ends off and prepped the cord for new plugs.

View attachment 234771

I would not have known anything was amiss unless I had the victron chargers and looked at the charge profile, something I regularly check when I check the smart shunt to make sure everything got charged up they way I was expecting. I use a #12 AWG extension cord which is rated for 20A’s and the draw was 11A’s.

One thing that I noticed that I don’t like about his extension cord is that there no AWG markings on the jacket of the cord, and when I stripped the outer casing back none of the internal wires are marked either. I used my strippers on the #12 setting and it stripped the wires correctly but I find that irregular that there was no wire size markings anywhere. Whereas the replacement cord I grabbed out of the shop was clearly marked on the jacket with the wire size and the temp rating which is important in determining the amperage rating of the wire. The ampacity of 12 AWG copper wire is typically rated between 20 to 30 amps, depending on the insulation type: 20 amps for 60°C insulation, 25 amps for 75°C insulation, and 30 amps for 90°C insulation.

Its a new season and we talk about what maintenance needs to be done so be sure and give your electrical cords a good visual inspection looking for discoloration in the jacket of the cord, and after your battery charger has been plugged in for a hour or so have a feel to see if there are any hot spots. If you find any irregularities in the plugs don’t just stop using them, cut the ends off so it will not get used again in that condition, any hot spots in the length of the cord, cut the ends off and throw the cord away. Just like a hammer with cracked handle, break it off so it cannot be used the risk isn’t worth it.


Note to self… never loan @FSH 210 Sport my extension cords!
 
Last edited:
That's odd that the main jacket didn't have any markings. I have one that doesn't have the markings on the inner wires, but I didn't find it odd, since the outer had the info for the whole cord assembly 🤔

Also, learn how to wrap cords, don't "elbow wrist wrap" them, you'll end up twisting the inner conductors and end up with garbage pigtailed ends and hot spots along the cord
 
That's odd that the main jacket didn't have any markings. I have one that doesn't have the markings on the inner wires, but I didn't find it odd, since the outer had the info for the whole cord assembly 🤔

Also, learn how to wrap cords, don't "elbow wrist wrap" them, you'll end up twisting the inner conductors and end up with garbage pigtailed ends and hot spots along the cord
People that elbow-wrist wrap should be deported.
 
Just like a water hose, you want to stretch the entire cord out, then pull it towards yourself while you create even loops. 😎
 
I use ELEGRP for most of my ends, and twist locks.

https://a.co/d/7KuXriP
Thanks!!

By the way, I have had this cord for quite a few years and never had an issue with it before. I do not like the molded ends that the cords come with.

I used to make up a lot of cords at work and couldn’t remember the ends we used then, a lot of them were Class 1 Division 1 rated cords, but there were a lot of twist lock three phase cords, single phase cords and normal 120VAC cords.
 
I use ELEGRP for most of my ends, and twist locks.

https://a.co/d/7KuXriP

I've used these for several remixed cords as well, and they're great. There's a few reports of one end being difficult, can't remember which (male/female), but that hasn't been my experience at all. Also almost $3-5 less, per end, when I was trying to find these. Prices have seemed to stabilize, but that's the reason I tried these in the first place
 
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