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5. INSTALLING AND CONNECTING THE BATTERIES
The Integrel system works equally well with both lead-
acid and lithium-ion batteries. The type and number of
batteries will have been determined during the system
design phase and the choice is influenced by a number
of factors:
• Typical 24 hour AC and DC power consumption
• Maximum loads seen on all circuit types
• Desired period of autonomy (“silent operation”)
• Typical 24 hour operational profile
Battery Choice and Installation
5.1
We currently support the following battery
manufacturers: Torqeedo, Victron, Relion and
Mastervolt. These weigh in excess of 25kg each, so
consideration must be taken as to where they are
sited, supported and secured.
5.1.1
It is important to note that battery
age, chemistry, brand and capacity must
not be mixed. This applies not only to the
batteries within each bank but also across
all banks. If you chose to add another
bank of batteries at a later stage, these should
be monitored for a full charge and discharge
cycle. If any discrepancy is seen between new
and old banks, all old banks must be replaced.
5.2
When unpacking lead-acid batteries, be sure to
check the voltages. They should all be above 12.8V
and should have a difference of no more than 0.2V
between batteries.
5.3
With lithium-ion batteries, it is common practice
to ship these at or below 50% state of charge (SOC).
In contrast to lead-acid batteries, lithium-ion batteries
do not like being left at 100% SOC. These batteries will
not balance individual battery voltage if they are not
properly synchronized before linking together in series.
For this reason, it is common practice to charge each
battery to a certain voltage stipulated by the battery
manufacturer before connecting batteries together
in series. Please refer to the battery manufacturer’s
installation instructions for details on this procedure.
**This procedure is vital for a system to work
effectively and for the useable capacity to be
maximised. Please refer to the battery manufacturer
documentation for more information**
5.4
Once you have confirmed the batteries are in good
condition and correctly charged, a suitable location
should be found where the batteries can be mounted
and secured properly. The best solution is to mount
the batteries close to each other with a suitable air
gap between blocks. Batteries should be packed
and secured so they will not move should the boat
encounter rough seas. If it is not possible to mount
batteries in one area, cable lengths between batteries
should be kept as short as possible 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 batteries or battery banks can
cause imbalances between them.
5.5
Link bars or cables should be fitted and torqued to
the battery manufacturer’s specifications.
5.6
A high interrupt current fuse (such as a Class T
or ANL fuse) should be fitted as close as practically
possible to the positive battery terminal, this will
protect the battery from a short circuit and should be
rated at well above the maximum expected load. A
breaker should also be fitted to protect the cable from
overcurrent. This should be fitted as stipulated in the
schematic for the individual installation.
5.7
In some cases, a battery terminal stud may be
supplied, which allows the battery bank sensor to
be fitted right next to the battery bank. If a terminal
stud is not supplied, or will not fit for the particular
installation, it is recommended that the battery sensor
is fitted over one of the battery cables (it may be
necessary to fit the sensor before crimping the final
terminal on to allow the sensor to pass over the cable
end). The chosen cable must take the entire bank
current - this could be a positive or a negative cable,
but not an intermediate link cable.
***Do not connect any battery bank until ALL other
48V wiring is complete***
**Always follow battery manufacturers installation
and application instructions**
5.8
The Integrel safety switch should be fitted as
close to the battery bank as possible, with no other
connections between it and the battery other than
the primary fuse (all load and charge sources need to
be on the switched side of the safety switch, not the
battery side). When a battery bank reaches a critical
low voltage or high temperature it will automatically
disconnect the bank to prevent damage to the battery.
The positive cable connects to the 48V positive
battery terminal, and the negative cable connects to
the negative terminal. If connected to the Integrel
data bus, it can also monitor and report other fault
conditions on the bus. Some battery types require
specific interfacing between the battery BMS and the
safety switch to allow disconnect and control directly
from the battery. This may require an optional wiring
loom as it is battery and model specific. Please contact
Integrel for more information as required, this should
be considered as part of the initial specification and
schematic process.
The main battery cables connect directly to the main
terminals. This should be done with the switch in the
off position, by pulling up on the knob. This knob
allows manual activation of the switch should it be
required.
