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Steve19

Battery Switch Problems

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2016 R200

Coming yesterday cruising along on plane and the everything shut down! Tried going to battery two, nothing.  The switch felt loose so I checked inside the console .  The back of the battery switch was cracked all the way around and was loose. I got it to hold together and made it the dock.  Inspecting it at home the whole back of the switch fell off in my hand (cables still attached)  I obivousijy need a new switch.  Has anyone replaced a switch?  Is it something I can do or do I need  mechanic?

 

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I may be mistaken, but I think at 2016 is still under warranty and the dealer should fix. From Robalo's facebook page:

Robalo's 5 Year Premiere Protection Component Warranty Promotion is going on now as well as Yamaha's 5 Year Engine Warranty. There's never been a better time to buy your brand new Robalo. Act fast.

As for doing it yourself, I removed my power panel due to a bad circuit breaker. After having worked on electronics for 30 years, the only difficulty was in not having double jointed elbows to get to parts of it easier. I think if you do your own car maintenance or house wiring it wouldn't be too hard to do. Just remember to label or mark cables so you know where they go back (unhook battery cables first!). Also, if it was me having to change it, I'd probably opt for a different switch manufacturer ( Blue Seas ). I think the Amazon Blue Seas switch is probably the right one, but check first.

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Mine did basically the same thing.  Since my dealer is about 75 miles away, I went to West Marine and picked up another switch.  Install was pretty straight forward and it took about 30 minutes at most.  As it was installed, it looked like there was quite a bit of tension on the housing which could have caused the breakage.  I used a couple of larger washers as backing plates for the screws that holds everything in place.  No issues since then.  Don't remember the exact price, but best I can recall it was about $30 to $40 for the switch.

 

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Thanks for the replies.  I am far from my home dealer (in the Keys). Found a dealer down here but had no way to get the boat there. (Back on the rack at the house rental). Service department was familiar with the problem, must be a common one.  It would have been covered if I could get the boat to them and would have to wait.  I decided to try and fix it myself they had the switch n stock.  After getting the old switch apart ( took pictures of he wiring first) the new switch was slightly bigger so had to ream out the hole in the template in the console .  After a lot of filing, it fit and got everything back together, all seems good.  I will test it out today while chasing Yellowtails!

 

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After reading about the Broken Battery Switch syndrome in this discussion and also here, I recently discovered the battery switch on our 2013 R180 fractured while stored for the winter in our warmed garage.

There was sufficient slack in the battery cables to move the electrical panel away from the bulkhead beneath the starboard stern jump seat...

37442182565_6d470372e6_o.jpg

 

...however, tension from the shorter cable on the panel may have contributed to the switch's failing...

39837673805_31a9be7681_o.jpg

 

Because our R180 is beyond Robalo's warranty period, I reviewed the switch manufacturer's website and found a surprising guarantee : "Blue Sea Systems stands behind its products for as long as you own them. Blue Sea Systems will replace or issue a credit for any of its products found to be defective in materials or manufacture."

After e-mailing Blue Sea Customer Service (conductor@bluesea.com) the basics of my R180 ownership and a photo of the failed M-Series dual battery switch, Blue Sea sent me a free replacement switch, which has been redesigned & significantly improved to avoid the fracturing many of us have experienced...

38922490810_6cbfb93cf0_b.jpg

 

The improved switches bear a sticker with the word "Revised"...

40689634842_f0da535466_o.jpg

 

Blue Sea also offers this advice on installation of their revised M-Series switch...

m-Series Battery Switch Installation Tips

  1. Proper terminal stud torque: 120 Inch pounds max. Over torqueing will damage internal assemble bosses and lead to future failure.                          
  2. Wire and cable support: The wires and cables attached to the M-Switch must be supported. The case cannot support multiple large cables and may fail if cables are left hanging from the terminal studs. ABYC recommends support every 18 inches max. We recommend no strain from cables, either hanging or from tight radiuses, be allowed to exert force on the back case of the switch.
  3. Flat mounting surface: Insure mounting surface is flat. Mounting on a curved or irregular surface may distort the case when tightening fasteners.

 

If your Robalo was originally fitted with a Blue Sea battery switch and it suffers the Broken Battery Switch syndrome outside Robalo's warranty period -- or if your dealer is too distant to return to -- then it's worthwhile to contact Blue Sea Customer Service (conductor@bluesea.com) for a free & improved replacement switch.

If you've already paid for a replacement battery switch because of timing or you not knowing about Blue Sea's guarantee, then it's worthwhile to contact Blue Sea Customer Service (conductor@bluesea.com) for a possible reimbursement.

Post-repair edit:

On our 2013 R180, the screws used to assemble the fractured switch to the electrical panel faceplate were #8-32 flat head machine screws, while the original and revised switches are designed for #10 machine screws. Use of the undersized #8's leaves the nylon-inserted nuts freewheeling and sitting too low to get a wrench onto.

If you also experience this, remove the rubber boots from the front of the circuit breakers and push them out the back of the electrical panel faceplate. This frees you to remove the electrical panel from within the starboard jump seat compartment and able to remove the undersized screws above deck.

Four #10-32 x 1 1/4 machine screws and nylon-inserted nuts make installing the revised switch much easier, even though the space for reattaching the battery cables is tight.

The project can be DIY if you're familiar with using 11/16 & 9/16 wrenches & sockets and a phillips screwdriver.

And finally, a throwable cushion on the deck makes kneeling down much more comfortable.

Good luck!

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Thanks so much!  This Just happened to me last night.  I've already bought the replacement part from west marine.  I'll contact Blue Sea for reimbursement. 

Also your description of the  nuts that are hard to get a wrench onto is right on-.  These are the circled ones below right?  I struggled to get 2 of them off last night (after I had to be towed to the Dock).   They just spun when using the Philips head and I couldn't  get a good grip on them with Pliers or anything. 

 

image.png.226408a62493114224e772914507e329.png

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Very sorry to learn that a failed switch left you stranded and in need of a tow, but I'm glad the posted information is useful to you.

In our case, the redesigned replacement switch shipped out of Mexico two days after I first e-mailed Blue Sea Systems, and it arrived four days later.

The customer service rep was sincerely apologetic for the trouble the failed switch caused us.

Good luck!
 

 

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The battery switch on my R207 went bad as well. Last time out, I noticed switching to battery one didn't take right away. Had to switch it back and forth from off to 1 a couple of times before it finally took. Today I found out it only works on battery two. Won't be going out again until it's replaced. I'll be calling my dealer tomorrow. 

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Switch has been Replaced.  It wasn't fun but i'm happy that I now have a solid Switch.

Thanks so much for the advice haz.  Removing the rubber boots from the front of the circuit breakers and pushing them out the back of the electrical panel faceplate was SO helpful-  Getting unfettered access to the plate to swap out the switch was Key!.  Also the tip to swap out the machine screws was also super helpful.

 

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One thing just occurred to me-  If so many Robalo Owners have had this issue- why isn't there a recall? I know that my boat was routinely serviced by the Robalo Dealer that I bought it from in February and if there was a recall this could have been avoided. 

I am not asking this question as a complaint but more of a real concern for the safety of other owners who's switch hasn't failed yet. 

My switch failed suddenly with little warning.  I was fishing in the Piscataqua River in NH.  The Piscataqua is a busy commercially used River that separates NH and Maine- with a notoriously Strong current (37th fastest tidal current in North America).  I noticed that my chartplotter had shutoff then restarted a couple of times within  a few minutes.  I immediately started to head back to my slip and my boat lost all power JUST as I had reached a safe area where I was able to anchor and wait for a tow.  There are a lot of "what if's" here that to be honest I'm having a hard time shaking. What if i hadn't made the decision to move?  what if my kids were on board...?

 

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3 hours ago, MB19565 said:

why isn't there a recall?

I'll echo this. As you stated, this could be a potential safety issue. I was was 20 miles offshore when I realized that the switch only worked on battery two. In the afternoon, the winds and waves kicked up and it got pretty sporty out there. Would have hated waiting for a tow in that. Not only that, what kind of potential long term damage could these intermittent connections do to the electrical systems? When I owned a 150 etec G1, it was well known how sensitive those engines were to voltage fluctuations. Wreaks havoc to the EMM.  

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In an effort to determine if Blue Sea Systems would proactively offer New Revision design m-Series replacements for unbroken Old Revision design switches,  I reached out to the Blue Sea Systems technical service rep who processed my switch replacement warranty claim, and I got the following reply:

"We always strive for happy customers. We have an “As Long as Your Own it” warranty and any customers that have issues are encouraged to contact us for replacements either at Conductor@Bluesea.com or TechSupport@Bluesea.com."

I interpret that response to mean "ask and you shall receive".

Send them an e-mail describing your ownership of a boat with a Blue Sea Systems Old Revision design m-Series battery switch installed; and perhaps, document that fact with a photo showing the red-cased Old Revision design m-Series switch in place on your boat; and express your awareness of their improved New Revision design m-Series switch, and express your awareness that many Old Revision design m-Series switches have spontaneously failed and left some boat owners stranded on the water, something you absolutely wish to avoid; request a warranty replacement for your Old Revision m-Series switch, so that you can gain renewed confidence as a Blue Sea Systems customer from having the warranty replacement New Revision design m-Series battery switch installed on your boat.

I expect you'll probably receive a no-cost replacement within a week.  Please let me know if it turns out that I'm wrong.

Blue Sea System's warranty response convinced me. I bought and incorporated a New Revision design m-Series switch in our R180's 4-bank battery charger installation.

Good luck!

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Thanks haz! I emailed them yesterday and got a response and confirmation of a new switch (newer revised version hopefully) being sent to me within an hour. Great customer service. Took a couple of pics of the switch on my boat yesterday. While I was at it, I checked the switch and realized it had completely failed. Did not work on any battery. Guess I was luckier than I thought to make it back last time without a tow. I was going the dealer route, but they're always busy and who knows how long it'd take for them to get to it. Besides, it's fun working on your boat. B)

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I contacted Blue Sea Systems and they are shipping me a new switch, mine is fine, but I expressed concern.


Edit - took them over a month to finally ship the switch.  Probably will install later this Fall, or in the Spring, since the boat isn't used from November - April.

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Just wanted to update this. Had to bring the boat to dealer since the battery switch wasn't the only problem. Turns out the 40 amp DC main breaker was inoperative. All replaced and covered under warranty. 

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