TRAINING AND
INSTALLATION GUIDE
ADVANCED
GENERATOR REPLACEMENT
TECHNOLOGY
Page 1: ...TRAINING AND INSTALLATION GUIDE ADVANCED GENERATOR REPLACEMENT TECHNOLOGY...
Page 2: ...ng with the installation of the Integrel system Nothing in this guide supersedes these two standards and if conflicting information is found the standards will always prevail Target Audience Assumptio...
Page 3: ...ies Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin WARNING Explosion Can cause severe injury or death Relays in the battery charge...
Page 4: ...disconnecting the battery controller wiring harness and engine electronic control module ECM WARNING Short circuits Hazardous voltage current will cause severe injury or death Short circuits can cause...
Page 5: ...re injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Refer to the Health and Safety Executive s publications found at http ww...
Page 6: ...nerator and delivers all of the power that you need to make living on board as comfortable as living at home For the boat builder the Integrel system simplifies the electrical energy system substantia...
Page 7: ...em Schematic 11 5 Installing and Connecting the Batteries 12 a Lithium ion 12 b Lead acid 12 6 Battery Bank Sensors 13 7 48V DC System 13 8 Controller 14 9 Inverter 16 10 DC DC Converter 16 11 Screen...
Page 8: ...ct 12v negative busbar xxA 30A Integrel system boundary 48 12 5A breaker 4mm 20A breaker 400A MRBF midi 30A midi 30A midi ANL class T 20A o p positive busbar To existing 12 24v Engine start battery Pe...
Page 9: ...em are Batteries for energy storage either lead acid or lithium ion configured for 48V DC Inverter charger to convert electrical energy stored at 48V DC to 110 240V AC It also allows you to charge you...
Page 10: ...aring in mind that cable lengths should be kept to a minimum to reduce cable losses Details of recommended cable sizes are given in Annex B Most vessels have conduits for major cable runs and these sh...
Page 11: ...boat be left without shore power Controller The main controller should be sited in a dry location within a 3m cable run of the generator The system needs reasonable airflow and under heavy load can b...
Page 12: ...ible and all link cables should be made of at least 70mm2 tinned marine cable It is important to try and keep all batteries in the system at a similar ambient temperature as differences between batter...
Page 13: ...2V and 24V battery banks 7 5 Run cables between the busbar and the battery bank s but do not connect Important Always ensure the 48V system is isolated before working on it Ensure a fuse breaker is ap...
Page 14: ...negative to the boat s negative 8 3 2 Working your way away from the controller the first connection you will see is the two way Molex plug for the gear detect switch This plug should remain connected...
Page 15: ...is redundant If the throttle control is already connected to the engine loom it may be possible to pick up the gear detect via the engine CAN BUS network in this case the engine ECU adapter must be u...
Page 16: ...sitive cable from the 48V busbar through a suitably sized circuit breaker or fuse to the 48V positive terminal on the DC DC converter via the supplied switch 10 3 Run in and connect the same sized neg...
Page 17: ...better to bring all cables to the junction box where possible 12 4 We operate a CAN bus system For this to work properly we need two terminating resistors connected to the data bus The junction box an...
Page 18: ...ges to blue 13 7 One at a time switch the battery banks on If you locked the safety switch out see point 13 2 during installation return the knob to the correct position before you do this 13 8 Look a...
Page 19: ...attery voltages were All 48V battery banks have been on shore power charge for at least 24 hours Owner has been briefed about the workings of the system what to expect in terms of output with their pa...
Page 20: ...0A midi ANL class T 20A o p positive busbar To existing 12 24v Engine start battery Permanently live 12v busbar 4mm 48 12 5A breaker 30A midi 20A o p Data cable to sensors on House bank 200Ah 200Ah 48...
Page 21: ...M 4 M 4mm 6mm 6mm 10mm 10mm 16mm 25mm 25mm 35mm 35mm 19 M 6 M 2 5mm 6mm 10mm 16mm 16mm 25mm 35mm 35mm 50mm 70mm 95mm 24 M 7 M 4mm 10mm 16mm 25mm 35mm 50mm 50mm 70mm 95mm 120mm 30 M 9 M 25mm 35mm 50mm...
Page 22: ...22 151 103 9 TOP 19 30 5 INTEGREL 5 SCREEN CUTOUT Annex C...
Page 23: ...p 3 V tap 4 0 volt tap thermistor thermistor thermistor thermistor 0 volt tap V tap 1 V tap 2 48V 48V 2 x 12V batteries total 24V thermistor thermistor 0 volt tap V tap 1 V tap 2 24V 24V 12V 12V therm...
Page 24: ...Field 5 mm Ring Terminal J1939 Plug J1939 Adapter Loom Optional Gear Detect Gear Detect Gear Detect Gear Detect Main Power to Integrel 0V Main Power to Integrel 12V Engine spacific plug Gear Detect pl...
Page 25: ...el system will need to be configured specifically for the engine and batteries fitted This is done through a mobile based app currently Android only iPhone to follow once Apple have qualified it as su...
Page 26: ...s These include a PIN code to allow login on secured systems use PIN 12345678 on unsecured systems a name of the vessel for easy reference an email address of the installer and a brief description of...
Page 27: ...e When the correct battery is displayed press the Edit Settings button After a short pause while the settings are requested you will enter the battery configuration page The first important setting to...
Page 28: ...el support Bank Capacity this should be set to the total amp hour capacity of the battery bank This needs to be correct to allow the system to track remaining capacity Min SoC this needs to be set to...
Page 29: ...terybankisdisconnected so no current is flowing and press the Set Current to Zero button If the Integrel system is being powered off a particular battery bank you may need to temporarily power it exte...
Page 30: ...a standard Integrel setup if this needs to be changed please contact Integrel for advice Use CAN bus gear detect a lot of more modern engine installations have a start inhibit wired directly into the...
Page 31: ...ectrostatic Discharge EN 61000 4 3 2006 Radiated RF Immunity 80 MHz to 2 GHz EN 61000 4 4 2004 Fast Transient and Burst Immunity EN 61000 4 5 2005 Surge Immunity EN 61000 4 6 2006 Conducted RF Immunit...
Page 32: ...s case a 50kW engine with a 700 to 3200 RPM range The true output is also dependent on electrical load temperatures and battery status When in neutral power generation is controlled to maximise fuel e...
Page 33: ...EMENT TECHNOLOGY Contact Triskel Marine Limited Unit 1 Marine Renewable Energy Park North Quay Hayle Cornwall TR27 4DD United Kingdom 44 0 1736 755466 enquiries triskelmarine com www triskelmarine co...
