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13. FINAL CONNECTIONS AND COMMISSIONING
13.1
Check all 48V connections for correct connection
and tightness.
13.2
With the battery switches locked off (turn the knob
90 degrees to the ‘off’ position –
this feature is only
intended for use during installation
), connect all 48V
battery banks. Be sure to include the tap cables for the
bank sensor and battery safety switch at this time.
13.3
Turn the Integrel system on at the Integrel switch
panel.
13.4
IMPORTANT!
At this point the system will require
configuration using the Integrel setup application. Please
see annex F for details on this.
13.5
If there are any issues with the installation, there will
be a beep from the display screen and an error displayed.
Common installation errors are incorrect or missing
voltage or temperature sensors, or other cabling issues.
The screen errors will pinpoint as closely as possible the
source of the fault, which should be rectified in order.
A ‘Low system voltage’ is an acceptable error, as this
message means that all sensors are functioning correctly,
but the main battery switches are open. This message
should clear when you reach stage 13.7.
13.6
It is important to set the zero reference of the
sensors. Plug in the configuration loom (supplied to
installers on request, not a standard item), and connect
to an independent 12V power source that is not being
monitored by the sensors.
**It is possible to set the zero point and current polarity
through the setup app, please see Annex F. The
following instructions are to set up sensors directly
during installation. Either method is acceptable**
13.6.1
With all battery switches off (including
any form of charging) and the DC-DC
converter(s) off, go to each battery sensor
and insert an object such as a 3mm allen key
into the “reset” hole. Press and hold the zero
button until the blue light comes on. It is
important to release as soon as the light
changes 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 at each battery bank current readings on
the display screen. For each bank in turn, apply a load
or charge to ensure the polarity is correct. If you are
discharging, the power figure should read negative kW.
If you are charging, power displayed should be a positive
figure.
13.8.1
If the current flow on the sensors is
incorrect, press the “reset” button again. This
time, hold the button past the point at which
the blue light comes on and release when the
blue light goes off again. This will change the
polarity. Now repeat step 13.6.1 to properly
set the zero on that bank.
13.9
Remove the configuration loom and separate the
12V source and return to the boat’s power for the system.
13.9.1
Switch the DC-DC converters on at the
Integrel panel.
13.10
Start the engine. If a connection to the engine ECU
had been made, the generator will not begin generating
until the engine coolant reaches 30
o
C. After this point,
the generator will begin to work. The generator page will
show an output in kW.
13.11
Charge the 48V batteries on shore power for 24
hours. This will ensure the state of charge figures are
correctly setup.
13.12
Unplug the boat from shore power.
13.12.1
With the electrical system under load,
(use electrical appliances to draw lots of
power off the batteries), allow the battery
state of charge to drop to around 80%.
13.12.2
With the electrical loads still on, start
the engine and run at 1/3 to 1/2 throttle. The
output should peak between 8kW and 9kW.
This will then drop to between 6kW and 8kW
as the generator will be limited on
temperature.
13.12.3
Check all 48V connections with a
thermal imaging camera. Ensure the system
has been running for several minutes under load
before concluding this check. Any connections
with high temperatures should be
disassembled and checked once the system
has been turned off, all batteries isolated and
the connection has been allowed to cool.
