One of the greatest challenges in setting up a marine electrical system that relies on selecting marine battery cables that have enough flexibility to work in the tight spaces often needed on the water. Because of the nature of the marine craft (and dock electrical systems as well), having a flexible cable that also fulfills the needs of the electrical system while being durable and safe is crucial. If flexibility is what you are looking for, there are two features of wiring that can be focused on to fit your needs.
The “stranding” or “strand count” is the primary measure of a marine battery cable’s flexibility; the higher the strand count, the greater the flexibility. Thankfully, most marine cables are considerably more flexible than their land vehicle equivalents, but there are still variances between the cables. If you know you are going to be repairing or building a system in particularly cramped spaces even by marine standards, go for the highest strand count possible, as this will give you excellent flexibility. Also, keep an eye out for “tinned” wires. Tinning wires refer to plating the copper strands of wire with a thin layer of tin. Tinning serves some beneficial purposes. It increases the cable’s resistance to moisture, oxidation, and corrosion. Specifically, in regards to flexibility, tinned wires are both more conductive and more durable. The additional durability granted by tinned cables can help stave off breakages that could otherwise result from bending the wire in a tight space. The increased conductivity means that a thinner cable may be able to be used, saving on much-needed space.
The other major factor affecting flexibility is the type of insulation used. PVC is a very common insulation type, which offers fantastic flexibility and is easy to identify. The Society of Automotive Engineers has a rating code that indicates whether a PVC insulated cable is approved for marine use. If you see a cable marked “SGT-M,” you can safely conclude that the cable is insulated with SAE approved PVC. Some marine cables use XLP insulation, which has higher temperature ratings, but notably less flexibility. Some tinkerers may be tempted to use welding cables instead of SGT-M since welding cables have very high flexibility and is usually more than capable of handling the current from a marine battery cable. However, you should avoid using non-marine rated cable for marine applications. While the cable has tempting benefits, the downsides outweigh them without a doubt. Non-marine cable simply cannot handle the moisture in the environment, nor can it cope with the corrosiveness of salt. If XLP insulated cables are not working, stick with SGT-M rated PVC cables, which come with the added benefit of being self-extinguishing in the unlikely case that damage does occur.
Balancing cost, strand count, and insulation can be a delicate process, but it’s worth the time investment. The challenges of marine environments demand careful planning, and it is often worth going with a slightly pricier, but higher quality cable to build a solid, trustworthy electrical system.
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