TRISKEL MARINE integrel Installation Manual
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TRISKEL MARINE integrel Installation Manual

Advanced generator replacement technology
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TRAINING AND
INSTALLATION GUIDE
ADVANCED
GENERATOR REPLACEMENT
TECHNOLOGY

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Summary of Contents for TRISKEL MARINE integrel

  • Page 1 TRAINING AND INSTALLATION GUIDE ADVANCED GENERATOR REPLACEMENT TECHNOLOGY...
  • Page 2 GENERATOR REPLACEMENT TECHNOLOGY Please Note Integrel is classified as an “extra low voltage DC system” and falls within the scope of the international standard ISO 10133:2017 and ABYC E11. It is strongly recommended that a copy of these standards is studied before proceeding with the installation of the Integrel system.
  • Page 3 SAFETY PRECAUTIONS & INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS. Electromechanical Battery Safety equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose WARNING life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.
  • Page 4 Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: CAUTION Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer’s instructions. Hazardous Noise Welding the generator set.
  • Page 5 Heavy Equipment WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the engine set until it cools. Servicing the alternator. Hot parts can cause severe injury or death.
  • Page 6 For the boat builder, the Integrel system simplifies the electrical energy system substantially. It is a complete power generation, storage, conversion and distribution system, providing all of the vessel’s energy needs in one consolidated package. The Integrel system also provides additional safety, engine and battery management tools for the end user for handling today’s modern lithium-ion battery banks.

  • Page 7: Table Of Contents

    Contents 1. Overall System Configuration and Components 2. Tools Required 3. Pre-fit Boat Survey 4. System Schematic 5. Installing and Connecting the Batteries a. Lithium-ion b. Lead-acid 6. Battery Bank Sensors 7. 48V DC System 8. Controller 9. Inverter 10. DC-DC Converter 11.

  • Page 8: Overall System Configuration And Components

    MRBF 48v negative busbar 12v negative busbar The core components of the Integrel system and their functions are as follows: • 9kW engine mounted generator - the source of • System controller - the black box which monitors and Integrel’s electrical power.
  • Page 9 Skills Required Installing an Integrel system is less complex and time consuming than installing a traditional generator, but still requires experience and guidance from Triskel Marine. It is intended to be installed by a qualified installer, with online access to Integrel’s system setup software and other Integrel resources.

  • Page 10: Tools Required

    2. TOOLS REQUIRED The Integrel system can mostly be installed with (8AWG - 4/0AWG) common electrical hand tools. Most marine electricians • Hot air gun will have: • Cordless drills for mounting parts • Insulated screwdrivers • Thermal imaging camera •...

  • Page 11: System Schematic

    On/Off Switch rectified to 48V DC. The loom with the smaller cables The Integrel switch should be left on at all times, brings temperature inputs from the engine, generator therefore it should be located in a position where it and ambient to further optimise generation.

  • Page 12: Installing And Connecting The Batteries

    5. INSTALLING AND CONNECTING THE BATTERIES The Integrel system works equally well with both lead- cable. It is important to try and keep all batteries acid and lithium-ion batteries. The type and number of in the system at a similar ambient temperature, as...

  • Page 13: Battery Bank Sensors

    6. BATTERY BANK SENSORS 6.1 Place the battery bank sensor over the sensor post 6.3 If using 4 x 12V batteries, use tap 1 for 12V or battery bank cable. (from 0V tap), tap 2 for 24V, tap 3 for 36V and tap 4 for 48V.

  • Page 14: Controller

    8.1 The positioning of the controller is important. 8.3.3 Continue working away from the It should be within a 3m cable run of the Integrel controller, the next terminal you will find is Generator (cable loom is supplied at 2.9m), and should the ambient temperature tap.
  • Page 15 CAN BUS network, in this case the engine ECU adapter must be used. These ECU cables are engine specific and various options are available. Please contact Integrel for advice, and this should be considered during the specification process.

  • Page 16: Inverter

    11.3 Connect the screen loom between the screen power source on the Integrel CAN bus system. interface box white 12-way Molex plug and the two deutsch plugs on the back of the screen. Though...

  • Page 17: Comms Cabling And Junction Box

    12. COMMS CABLING AND JUNCTION BOX 12.1 Find a clean dry place for the junction box as close 12.5 If a second junction box or second screen to the centre of the kit as possible and secure with interface box is to be used, you will need to make sure appropriate fastenings.

  • Page 18: Final Connections And Commissioning

    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 13.3 Turn the Integrel system on at the Integrel switch the blue light comes on and release when the panel.
  • Page 19 Engine The update file can emailed or downloaded from the • All nuts and bolts are correctly fitted and torqued to Integrel system website. This file should be copied to specification. a USB memory stick without changing the filename. • The belt is fitted correctly.

  • Page 20: Appendices

    APPENDICES...
  • Page 24 Controler black plug white plug Gear Detect alternative loom Gear Detect - Gear Detect + Ambient Temp 10mm Ring terminal Engine Temp 10mm Ring Terminal Engine spacific plug Gen Temp + 4mm Ring Terminal Gen Temp - 4mm Ring Terminal Field + 5 mm Ring Terminal Field - 5 mm Ring Terminal J1939 Plug...
  • Page 25 This is done through a mobile-based app (currently Android only, iPhone to follow once Apple have qualified it as suitable for deployment). With the system powered up, run the application, and click the ‘connect’ button to scan for the Integrel controller and establish a link: Once connected, you will be presented with a set of dials showing the real-time data from the first battery bank.
  • Page 26 Also available in the menu is the option to go in to ‘Setup’ mode. This is only for use by qualified installers and is not intended for end-user application - there is a separate view-only application for end-users. Choosing setup mode will prompt the installer for some details. 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 the boat.
  • Page 27 The Integrel sensors can work on 12V, 24V and 48V battery banks, made up of any number of 12V, 24V or 48V battery blocks (for example, a 48V bank made up of two 24V batteries, or four 12V batteries).
  • Page 28 Index Number – this allows sensors to be assigned to specific functions, for most installations leave this as 0 unless advised by Integrel 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.
  • Page 29 Each sensor also needs to be calibrated once installed. To do this, ensure that the battery bank is disconnected 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 externally, as described in the installation guide.
  • Page 30 Pulley ratio – different engines and installations require different configurations of drive pulley. A 2.6:1 ratio is the most common for a standard Integrel setup, if this needs to be changed please contact Integrel for advice.
  • Page 31 We, Triskel Marine Ltd 1 Marine Renewables Business Park North Quay Hayle TR27 4DD declare that the product Integrel marine generator replacement system is in conformity with Council Directives 2004/108/EC (EMC Directive) Maritime navigation and radio EN 60945: 2002 communication equipment and...
  • Page 32 3500 Engine revs (rpm) This chart shows the theoretical output profiles for a specific Integrel installation. In this case, a 50kW engine with a 700 to 3200 RPM range. The true output is also dependent on electrical load, temperatures and battery status.
  • Page 33 ADVANCED GENERATOR REPLACEMENT 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.uk www.integrelmarine.com...

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