Integrel
Product Datasheet
Version 1.5
October 2022
Integrel Product Data Sheet
1 Introduction
Integrel generates electrical power using a high efficiency, high-output large-frame alternator (sold as an On-
Engine Generator, or OEG). The OEG is belt driven from the PTO of the main propulsion engine and is typically
installed in the same physical space as a conventional second alternator. However, unlike a conventional
alternator, the power output and voltage of the Integrel OEG are actively managed to ensure that propulsion is
always prioritised and engine loading is optimised.
Whilst the main propulsion engine is running, the OEG produces a variable voltage, variable frequency three-
phase electrical output which is passed to a custom designed Controller. A high-quality bridge rectifier within
the controller converts three-phase power to a precisely controlled DC output. The DC output is electronically
limited to 9kW/170A at a nominal 48 volts. A relatively high DC voltage helps to reduce losses in the OEG and
keeps cable size, cost and weight to a minimum.
DC power from the Controller passes to a 48 volt power busbar where it is distributed to the vessel’s electrical
consumers including:
• DC-DC converters/chargers used to power appliances connected to 12V / 24V house batteries
• AC inverters to power mains appliances at 110V/220V including fridges, freezers, ovens, hobs, etc.
• Heavy DC loads such as 48V bow thrusters, winches, and air conditioning (saving weight, cost and
complexity compared to powering these items with AC inverters).
Any power not used directly is stored in a large bank of 48 volt batteries, with the aim being to fully charge the
batteries by the time the propulsion engine is shut down at the end of the day. After engine shutdown, power
to the entire vessel is supplied from the energy stored in the battery bank.
1.1 The Intelligent Generation of Electricity
Integrel exploits the fact that there is a significant power gap between the optimum efficiency load line of an
engine and the load applied by the propeller (the green and blue lines respectively in the following diagram).
The generator is used as a precisely managed variable load in addition to the propellor load to operate the
engine at or near optimum efficiency. The result is one engine doing two jobs: turning the propeller and
generating electricity, with both tasks delivered with the best possible efficiency to save fuel.
Since boat speed is locked to propeller speed, with a well governed modern engine, adding the generator load
does not change the boat speed. As a practical example, at a cruising speed of 1700 rpm with a typical 60 kW
engine, the propeller load is about 8 kW and the optimum engine load is about 22 kW, leaving 14 kW excess
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Integrel Product Data Sheet
power. At this speed, the Integrel OEG produces 8 kW of electrical power and applies around 11kW of
mechanical load on the engine, moving the total engine load into the optimum operating area.
1.2 Design and Installation
The Integrel system is designed with a ‘safety first’ approach. The system has a high fault tolerance and is pre-
configured for straight forward installation. An engine bracket mounting kit is provided to suit various popular
engines from manufacturers including Yanmar and Volvo. There are no through hull connections, valves, fuel,
exhaust or cooling systems. The OEG itself is air cooled and, so far as possible, everything is ‘plug and play’ with
all connections clearly labeled. To streamline installation, Integrel provides a comprehensive installation
manual, together with on-site training for installers.
To avoid customer concerns related to engine warranty, Integrel maintains an independent worldwide engine
warranty policy. After thousands of hours of operation on many engines, not a single claim has been made.
1.3 System Specifications
Parameter Value
Supported Battery Types LiFePO4 (Lithium), GEL & Flooded Lead Acid
Communication System Integrel proprietary CANbus (with integrated 12V power)
Third-party Interfaces J1939/NMEA2K to read BMS and Engine Data
Configuration USB with Integrel Configurator Software
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Integrel Product Data Sheet
2 Integrel Controller
Parameter Specification Units
Input voltage 12 V (min) – 14 V (max) V
Current consumption 5.5A Peak A
Current Sensor Type Stabilised hall effect -
Controller sleep mode, current draw 13 mA mA
Generated current (maximum) 170 A A
Generated power (maximum) 9000 W W
Generated power (at 1700 RPM engine speed, 60kW engine) 7.5-8.5 (Temperature dependant) W
Operating temperature range (ambient) 0 to +65 °C °C
Rectifier efficiency (AC-DC) 99 % %
Internal 48V DC output fuse 250 A, 58 V Link fuse -
Internal CANbus power fuse 2 x 1.5A, 12 V, 5x20 Cartridge style -
Internal Field Coil fuse 20 A, 12 V, 5x20 Cartridge style -
Internal DC/DC fuse 3 A, 57.6 V, 5x20 Cartridge style -
Network Protocol Integrel proprietary (Argo) CANbus -
Humidity (Non-condensed) 95 % (max) %
Weight 5.4 kg kg
Dimensions 240 (H) x 105 (D) x 290 (W) mm
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Integrel Product Data Sheet
3 Integrel Generator (OEG)
The Integrel alternator is referred to as an On-Engine Generator in all Integrel literature.
Parameter Specification Units
Type Asynchronous -
Voltage output rating 56 V V
Cooling Air cooled -
Operational temperature limits 0 to 180 °C °C
Nominal operating temperature 100 - 120 °C (software configurable) °C
Weight 11.9 kg kg
The following graph shows the typical output power and applied torque of the Integrel OEG. The OEG RPM is
typically configured for a speed of 2.6X engine RPM.
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Integrel Product Data Sheet
4 Smart Switch
Parameter Specification Units
Smart Switch max feed through current 400 A / 500 A (depends on version) A
Smart switch 48V tap current draw 250mA A
Operating temperature range 0 to +65 °C °C
Closing time (close) 15 ms ms
Opening time (open) 8 ms ms
Bounce time <5 ms ms
Switch cycles (max) 100,000 cycles
CANbus terminator option Yes -
Humidity (Non-condensed) Max 95% %
Weight 1.3 kg kg
Dimensions 148 (H) x 100 (W) x 135 (D) mm
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Integrel Product Data Sheet
5 Battery Bank Sensor
Parameter Specification Units
Voltage taps (total current consumption) 0.3 mA mA
Number of voltage taps 5 (0V, 12V, 24V, 36V, 48V) -
Integrel Argo CANbus connections (RJ45) 2 -
Humidity (Non-condensed) 95 % (maximum) %
Weight 197 g g
Dimensions 30 (H) x 129 (D) x 63 (W) mm
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Integrel Product Data Sheet
6 Integrel Display
Display
Parameter Specification Units
Screen size (diagonal) 5" Inches
USB 1 x USB A -
Integrel Argo CANbus connections (RJ45) 2 -
Wi-Fi Yes
Max Current 350mA (@12V)
IP Rating IP64
Weight 200g grams
Dimensions 38 (H) x 102 (D) x 149 (W) mm
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Integrel Product Data Sheet
7 Integrel Junction Box
Parameter Specification Units
Integrel Argo CANbus connections (RJ45) 8 -
Integrel Argo CANbus terminator option Yes (factory installed) -
Humidity (Non-condensed) 95 % (max) %
Weight 92g grams
Dimensions 23 (W) x 41 (D) x 140 (H) mm
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Integrel Product Data Sheet
8 Supported Brands
The Integrel system works in conjunction with various brands of power electronics and batteries. Integrated
system testing is performed with each brand of battery to ensure safe and robust operation. In addition, we work
closely with all supported vendors of power electronics to ensure seamless integration. Key battery and power
electronics partners include:
• Victron
• MG
• Mastervolt
• Lithionics
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Integrel Product Data Sheet
9 Supported Engines
Yanmar
• 3JH
• 3YM30
• 4JH45
• 4JH57
• 4JH80
• 4JH110
• 4JH-5E
• 4JH-5CE
• 4JH4-HTE
• 4LV150
• 4LHA-HTP
Volvo
• D2-40
• D2-50
• D2-60
• D2-75
• D3-110
Beta
• 75
Vetus
• 45
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