The Integrel system can mostly be installed with
common electrical hand tools. Most marine electricians
will have:
• Insulated screwdrivers
• Insulated spanners
• Standard spanners (metric and imperial)
• Allen keys
• Socket set
• Ratcheting insulated terminal crimp tool
• Non insulated terminal crimp tool 10mm
2
-120mm
2
(8AWG - 4/0AWG)
• Hot air gun
• Cordless drills for mounting parts
• Thermal imaging camera
• Independent 12V power source/battery
• Insulation strippers
You may not have a thermal imaging camera, however
we feel this is a crucial piece of equipment for checking
your work and ensuring there are no bad connections.
2. TOOLS REQUIRED
Prior to starting the installation, it is essential to carry
out a physical survey of the boat to identify where the
individual components will be fitted. This is particularly
important for the batteries which are likely to be the
largest and heaviest items. For specific sizes and weights,
please refer to our website. Batteries must be installed in
a dry space and well clear of any area where there might
be water ingress (see ISO 10133 for details). Ensure all
restraints and mounts are to a suitable standard.
Batteries
All batteries, but particularly lithium-ion, are sensitive
to temperature. It is essential that the batteries are
positioned in the coolest possible location in the boat
and there is plenty of air circulation around them.
lithium-ion batteries will automatically disconnect if their
internal temperature exceeds a given limit, which may be
as low as 45°c. If prolonged operation in high ambient
conditions is required, careful attention must be paid to
the manufacturers’ operating limits and battery choices
should be made accordingly. There may also be low
tempertature usage limits with some batteries.
Lead-acid battery spaces must be vented to the exterior.
If in doubt about the effect of the battery weight on boat
trim, consult a naval architect.
Cable Routes
Routes for cabling need to be identified as part of the
survey, bearing 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
should be used where possible.
Please note: the positive and negative power cables
should be run together to reduce stray magnetic fields.
These should always be kept clear of bilge areas. Data
cables, AC power cables and DC cables should be run
separately if possible.
Generator
The generator is mounted on the front end of the engine
and is normally driven from an additional pulley bolted
to the existing crank pulley. Depending on the make of
engine, the Integrel generator may extend outside the
normal envelope of the engine. Be sure to check that
there is sufficient room to accommodate any overhang.
Installation instructions are included with each specific
engine fitting kit.
Screen
The screen can be mounted remotely from the other
system components and should be positioned where
it is easy to see from the main saloon. The display has
been designed to show the battery state of charge and
voltage at a glance and it is useful to be able to see it
easily from all of the common spaces. The screen also
displays various alarms and alerts and must be accessible
in order to acknowledge and clear alerts. A template for
the screen cut-out is given in Annex C, or you can use the
supplied screen mounting panel.
Battery Switches
The main battery switches are solenoid operated and
are normally actuated automatically by the system itself.
They are also fitted with a mechanical actuator and need
to be accessible in case of an electrical failure. Ensure
you have a suitable location available for the switches.
Busbars
These are used as a primary means of connecting
common DC power cables. Ensure all connections are
booted and protected from short circuit.
Battery sensor
The battery sensor measures battery parameters such
as individual battery voltage and bank temperature. The
sensor then communicates with the controller, which
delivers the right amount of power to correctly charge
your battery banks as quickly and efficiently as possible.
3. PRE-FIT BOAT SURVEY
