8. CONTROLLER
8.1
The positioning of the controller is important.
It should be within a 3m cable run of the Integrel
Generator (cable loom is supplied at 2.9m), and should
also be located in a clean and dry environment. The
controller is designed to be bulkhead mounted with
the fans on the left, however it may be mounted in
either orientation. If bulkhead mounting in the portrait
orientation the fans must be at the bottom. The
controller can also be mounted on a horizontal surface
providing it is properly secured.
8.2
Once the correct location has been determined, the
controller should be mounted with four appropriate
screws, once the holes are marked. It is best to screw
the lower two screws in most of the way and slide
the controller onto these, before adding the last two
screws and tightening all four.
8.3
Connect the Integrel generator to the controller
with the two pre-made looms supplied. The first loom
has two Molex plugs (one black, one white) and is for
the data input, power to the controller and power
to the generator. The plugs should be fitted to their
appropriate holes on the controller.
8.3.1
You will notice there are a pair of cables
attached to the black plug that are separate to
the rest of the loom. These are the main 12V
power cables to power the system and
should see no more than 20A. The positive
should be attached to a breaker for the system
and the 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 if
you plan on using a neutral switch from the
gearbox, or if you plan on extending these
cables from the engine side of the loom to
the throttle control neutral switch. If you plan
on using a neutral switch nearer the Integrel
controller, you should separate this plug and
use the adaptor loom provided. It may be
necessary to extend this to reach the throttle
control. See Annex E.
8.3.3
Continue working away from the
controller, the next terminal you will find is
the ambient temperature tap. This will be
around 0.5m from the controller. It is a 10mm
ring terminal connected with a twin core
cable. Secure this to a bulkhead in the same
space as the controller.
8.3.4
The next twin core cable with a single
ring terminal at the end is the engine
temperature tap. This will be located at the
engine end of the loom and should be
positioned at the hottest point of the engine’s
fresh water cooling circuit, ideally the
thermostat housing. Ensure this cabling is
properly protected and secured to avoid any
damage from engine vibrations.
8.3.5
At this point you will be left with four
ring terminals, a pair of bare ends, and a 4-pin
plug on this loom. You will notice that there
will be two pairs of ring terminals, a pair of
4mm and a pair of 5mm ring terminals. The
4mm terminals are the thermistor
connections. These are to be fitted to the two
4mm studs on the back of the generator.
