Blue Sea Systems 8408 User manual

1. Disconnect all AC and DC power
Disconnect all AC power originating on or off the vessel. This includes
inverters, generators, shore power attachments and any other device
capable of supplying AC power to the ship’s circuits.
Disconnect the main positive DC cable from all batteries to eliminate the
possibility of a short circuit and to disable the inverter while installing the
distribution panel.
2. Apply Voltage Label
All panel components are sized for 12 or 24 Volt systems. Use the labels
provided to permanently identify the system voltage and its type (DC) as
required by ABYC. Apply the appropriate voltage label to the recessed
area on the front of the panel.
3. Select mounting location and cut opening
If this panel is to serve as your main shore power disconnect circuit
breaker, select a location which is not more than 10 feet from the shore
power inlet or the electrical attachment point of a permanently installed
shore power cord as measured along the conductors of the feed wires. If
it is more than 10 feet, additional fuses or circuit breakers must be
installed within 10 feet of the shore power inlet.
Select a mounting location which is protected from water on the panel
 frontandbackandisnotinanareawhereammablevaporsfrom 
propane, gasoline or lead acid batteries accumulate. The circuit breakers
used in marine electrical panels are not ignition protected and may ignite
such vapors.
Using the panel template provided, make a cutout in the mounting
surface where the distribution panel is to be mounted. Do not yet fasten
the panel to the mounting surface.
Marine Electrical Prod ucts
AC & DC Power Distribution Panel
PN 8408 / PN 3408 / PN 8508 / PN 3508
Specications
Material: 0.125" 5052-H32 aluminum alloy
Primary Finish: Chemical Treatment per MIL-SPEC C-5541CFinal
Panel Finish: Graphite color 2 part textured Polyurethane
Maximum Amperage: Varies by components; busbar maximum 100A
Voltage Rating: 8408 /3408 12 or 24 Volt DC* / 120 Volt AC Systems
8508 / 3408 12 or 24 Volt DC* / 230 Volt AC Systems
Inches Millimeters
Overall Dimensions: 15-3/4 × 10 400.10 × 254.00
*Congureyourpanelwiththesuppliedvoltageidenticationlabels.
Features
DC 8408 / 3408 / 8508 / 3508
•One100AmpereC-SeriesDCmaincircuitbreaker
•Eighteencircuitbreakerpositions,twelve15Amperebranchcircuit 
breakers installed
•DCdigitalmultimeterPN8248withremoteshuntandbatterybank 
selector switch
AC 8408 / 3408
•Eightcircuitbreakerpositions,one30AACMaincircuitbreakerandthree
15A branch crcuit breakers installed
•ACdigitalmultimeterPN8247
AC 8508 / 3508
•Eightcircuitbreakerpositions,one16AACMaincircuitbreakerandthree
8A branch circuit breakers installed
•ACdigitalmultimeterPN8247
Page 1 of 4
WARNING
]These instructions are intended to provide assistance with the
installation of this product, and are not a substitute for a more
comprehensive understanding of electrical systems. We strongly
recommend that a competent electrical professional perform the
installation of this product.
]If either the panel front or back is to be exposed to water it must be
protected with a waterproof shield.
]The panels must not be installed in explosive environments such as
gasoline engine rooms or battery compartments as the circuit breakers
are not ignition protected.
]The main positive connection must be disconnected at the battery post to
avoid the possibility of a short circuit during the installation of this
distribution panel.
]The shunt must be installed in the negative line to avoid damage to the
meter. Positive voltage applied to digital meter terminals #4 and #5 will
cause damage to the meter not covered by warranty.
]The vessel’s shore power cord must be disconnected form shoreside
power before installing this electrical panel.
]If an inverter is installed on the vessel its power leads must be
disconnected at the battery before the panel installation. Be aware that
many inverters have a “sleep mode” in which their voltage potential may
not be detectable with measuring equipment.
]If an AC Generator is installed aboard it must be stopped and rendered
inoperable before the panel is installed.
]Verify that no other AC source is connected to the vessel’s wiring before
the panel is installed.
Blue Sea Systems Inc. Phone [phone]
425 Sequoia Drive Fax [phone]
Bellingham, WA 98226 USA www.bluesea.com
Installation Set Up
1. Select positive feed wire and negative return
Determine the positive feed (red) and negative return (black or yellow)
wire size by calculating the total amperage of the circuits that will be
routed through the panel. Blue Sea Systems’ electrical panels are rated
at 100 amp total capacity. The positive feed wire must be sized for 3%
voltage drop at the 100 amp panel rating or the maximum amperage
that will be routed through the panel in any particular installation,
whichever is less. It is recommended that the positive feed wire be sized
for the full panel capacity, which, in most cases, will require at least 2
AWG wire, assuming a 10 foot wire run between the panel and the
batteries in 12 volt systems. Refer to the Wire Sizing Chart for other
situations. In the case of panels with two or more columns of breakers,
jumpers from positive bus to positive bus and from negative bus to
negative bus should be the same size as the positive feed and the
negative return wires.
Remember that the length of the circuit is the total of the positive wire
 fromthepowersourceandthenegativewirebacktotheDCNegative
Bus. Be certain that there is a fuse or circuit breaker of the correct size
protecting the positive feed wire.
2. Install shunt, negative return and positive feed
The DC digital meter shunt must be installed in the negative line of the
circuit whose current is to be measured. Refer to the DC meter
installation and operation manual prior to installing the shunt. Review the
Theory of Operation, Use, Installation Overview, Installing Shunt, Wiring
Diagram and Wire by Wire Instruction sections. Observe all warnings
regarding the shunt installation.
Connect a negative return wire from the negative bus on the panel to DC
negative and ultimately the load side of the shunt. Connect a positive
feed wire from the positive bus on the panel to DC positive. Be certain
that there is a fuse or circuit breaker of the correct size protecting the
positive feed wire.
DC Installation
9089Rev.006
Questions and Comments
We invite your questions and comments. You may contact us at the address
below.Tondoutmoreaboutourfulllineofmarineelectricalproductsvisit
our web site at www.bluesea.com.
Guarantee
AnyBlueSeaSystemsproductwithwhichacustomerisnotsatised 
may be returned for a refund or replacement at any time. Reference Blue
SeaSystems’DigitalMeterinstallationmanualforspecicmeter 
warranty information.
1-800-548-1191 - http://www.partdeal.com - [email protected]

DC Installation (continued)
3. Install battery bank voltage monitor wires
The panel is supplied with a digital meter and switch to monitor the
voltage of three separate sources, usually the batteries. Connect a
 minimum16AWGredwirefromeachsourcetobemonitoredtoeachof
the corresponding input wires of the switch. There should be a 1 ampere
fuse in each positive wire near each source.
4. Install branch circuit wires
Determine the proper wire size for each branch circuit using the
guidelines in step 4. Verify that the standard 15 amp circuit breakers
installed in the panel are large enough for each branch circuit. Remove
and replace with a higher amperage any that are undersized. Connect
the positive (red) branch circuit wires to the load terminals of each circuit
breaker. Connect each negative (black) branch circuit wire to the DC
 NegativeBus.DONOTCONFUSETHEDCNEGATIVEBUSWITHTHE
 DCGROUNDINGBUS.
5. Optional—install grounding system wire
The grounding wire (bare, green or green with yellow stripe and normally
non-current carrying) should not be confused with the negative ground
wire (black or yellow and normally current carrying).
In Boatowner’s Illustrated Electrical Handbook,CharlieWingidenties
three purposes of DC Grounding:
1. Holding conductive housings of low voltage (under 50 volts) DC
devices at ground potential by providing a low resistance return
path for currents accidentally contacting the device cases.
2. Providing a low resistance return path for electrical current,
preventing stray currents that may cause corrosion.
3. Grounding metal electrical cases to prevent emission from inside
or absorption from outside of radio frequency noise (RFI).
ABYC requires that grounding wires be sized no smaller than one wire
size under that required for current carrying conductors supplying the
device to which the grounding wire is connected.
6. Installation of Backlight System
Connect the yellow negative wire to the panel negative bus. Do not
confuse with the AC neutral bus.
To activate the label lights by the boat’s battery switch, connect the red
positive wire to the DC positive bus. Do not confuse with the AC
hot bus.
To activate the label lights by an independent switch or breaker,
connect the red positive wire to the load side of a DC switch or breaker.
7. Optional Branch LEDs
This panel is supplied with LEDs pre-installed in all optional branch
positions. For future expansion of the panel remove the positive leg of
the LED from the negative bus and connect it to the load side of the
corresponding branch circuit breaker.
Note
This Blue Sea Systems electrical distribution panel is furnished with 15A
circuit breakers for DC branch circuits. These ratings will satisfy the vast
majority of marine circit protection situations. As shown in the Wire Sizing
Chart,even16AWGwire,whichistheminimumwiresizerecommendedby
ABYC, has an allowable amperage greater than 20A.
AC Installation
1. Install branch circuit wires
Determine the proper wire size for each branch circuit using the chart
below. Verify that the standard circuit breakers installed in the panel are
correct for each branch circuit. Remove and replace any that are
incorrectly sized. The circuit breaker must have a rating less than the
allowable amperage of the wire, yet greater than the circuit’s
continuous current.
Connect each branch circuit hot (black) to the appropriate load terminal.
Connect each branch circuit neutral (white) to one of the screws on the
neutral bus. Connect each branch safety ground wire (green) to one of
the screws of the safety ground bus.
Do not confuse the neutral current carrying wires (sometimes called
ground) with the green normally non-current carrying wires (sometimes
called grounding). These two wires must be connected only at the source
of power, nowhere else.
Wire sizing chart
Use the wire sizing chart below to determine the proper branch
and feed circuit wire sizes.
2. Install feed circuit wires
Install the feed wires from the shore power inlet or other AC source,
referring to the wire sizing chart to select the correct wire size. Connect
the black AC hot, white AC neutral and green AC safety ground as shown
in the illustration.
If the feed wires are from the shore power inlet or the electrical
attachment point of a permanently installed shore power cord and the
inlet or attachment point is more than 10 feet from this panel, an
additional fuses or circuit breakers must be installed within 10 feet of the
shore power inlet. The measurement is made along the conductors.
3. Optional Branch LEDs
This Panel is supplied with LEDs pre-installed in all optional branch
positions. For future expansion of the panel remove the hot leg of the
 LEDfromtheACNeutralBusandconnectittotheLoadsideofthe
branch circuit breaker.
Note
This Blue Sea Systems electrical distribution panel is furnished with 15A or
8A circuit breakers for AC branch circuits. 15A circuit breakers are used in
all 120V panels and 8A circuit breakers are used in all 230V panels. These
ratings will satisfy the vast majority of marine circuit protection situations.
9089Rev.006
Page 2 of 4
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1. Apply branch circuit labels and mount panel
Apply a label for each circuit from the label set provided. If the
appropriate label is not included, extended label sets are available
through retail suppliers, and over 500 individual labels are available
directly from Blue Sea Systems. Please go to www.bluesea.com to
 orderstockorcustomlabelsforspecicapplications.
Fasten the panel to the mounting surface using the screws provided.
2. Testing
 ]Reconnect the main positive cable to the battery terminals and turn
the main switch on to supply power to the panel. Turn on all branch
circuits and test the voltage at the panel. Compare this voltage to
the battery terminal voltage to determine that the voltage drop is
within 3%. With all branch circuits still on, test the voltage at one
device on each circuit to determine that there is a 3% or 10% drop
as is appropriate.
 ]Connect the vessel’s shore power and verify the Reverse Polarity
light is not illuminated. If the red Reverse Polarity light is on then
either the hot and ground or the hot and neutral wires have been
crossed. Starting at the panel, trace the connections back as far as
necessary to locate the error.
] Using a multimeter where the power source is connected to the panel
verify:
 PN8408/PN3408—120VoltAC
a. 120 volts between hot and neutral
(nominal, this may vary depending on source voltage)
b. 120 volts between hot and ground.
c. 0 volts between neutral and ground
 PN8508/PN3508—230VoltAC
a. 230 volts between hot and neutral
(nominal, this may vary depending on source voltage)
b. 230 volts between hot and ground.
c. 0 volts between neutral and ground.
] Turn on each branch circuit to verify power to each circuit.
] Review the AC and DC meter installation and operation manual.
Reference the Theory of Operation, Use, Installation Overview and
operations sections. Verify meter functions.
Panel Mounting and Testing
Reference
Applicable Standards
•AmericanBoatandYachtCouncil(ABYC)
Standards and Recommended Practices for Small Craft sections:
E-1, E-3, E-9.
•UnitedStatesCoastGuard33CFRSubPart1,ElectricalSystems
Useful Reference Books
•Calder,Nigel(2005).Boatowner’s Mechanical and Electrical Manual
(3d ed). Camden, ME: International Marine / McGraw-Hill.
•Wing,Charlie(2006).Boatowner’s Illustrated Electrical Handbook
(2d ed). Camden, ME: International Marine / McGraw-Hill.
Other Innovative Products from Blue Sea Systems
•360PanelSystem
•BatteryManagementSolutions
•ACandDCcircuitprotectiondevices
•WeatherDeckwaterproofcircuitbreakerpanels
•Fuses,fuseblocks,andBusBar
•Analoganddigitalmeters
9089Rev.006
Page 3 of 4
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ADDITIONAL BREAKER REQUIRED IF GREATER THAN 10 FEET
0.5 TO 2 AMP
FUSES
1 TO 2 AMP
FUSE
Wiring Diagram
AC/DC Power Distribution Panel
with AC & DC Digital Multimeters
PN8408/PN3408shownforreference
9089Rev.006
Page 4 of 4
1-800-548-1191 - http://www.partdeal.com - [email protected]