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Integrel - Generator Replacement

Discussion in 'Generators' started by SeaLion, Dec 13, 2018.

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  1. SeaLion

    SeaLion Senior Member

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    Interesting idea that can eliminate an internal combustion generator, in the right application of course.

    Use a monster alternator on the propulsion engine(s) to convert spare power into DC, store it in a battery bank and invert it when you need AC.

    See the Nigel Calder videos.

    https://www.integrelmarine.com/
  2. Pascal

    Pascal Senior Member

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    This pretty much what many sailboat rely on, although they usually skip the inverter parts as they don’t use AC power away from the dock

    It s fine with small propulsion engines but a complete waste for boats equipped with anything over a couple of hundred HPs
  3. bobhorn

    bobhorn Member

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    Current sailboat has a small alternator to charge the start battery and a big Delco to charge the house bank both on the propulsion engine. Same idea, just no smarts. Probably also more reliable.
  4. Lepke

    Lepke Member

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    I use a Magnum MS-PAE inverter that can be ganged to 16kw. My boat came with 2-14 kw generators. The po ran one all the time. The boat is wired with 120/240 AC as primary. Only bilge pumps, nav lights and bridge electronics are DC. The inverter supplies 120/240 from one box, so it makes tying it into the AC system simple. I have 48v banks and can anchor a couple days before I run a generator. I have a large house sized reefer and 2 freezers and all but emergency lights are AC. When the mains are running I keep the 48v banks up with a second alternator on one engine. Now I never run a generator when the mains are running.
  5. Ward

    Ward Senior Member

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    It's not a new idea, Steve Dashew's been doing that on all his powerboats and I think even before that on his sailboats: have a big battery bank and use a big alternator on the engine. All of his designs will run off the batteries for days, then if you use the main engines to move every few days you don't need a generator. On his more recent designs, there's enough space for enough solar panels that there's even less need for a generator.
  6. Capt Ralph

    Capt Ralph Senior Member

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    I'm looking for a high amp 48v alternator for a similar design. Where did you find yours?
  7. MBevins

    MBevins Senior Member

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    Look at Balmar, I have a 270amp on my system, very happy, although 12vdc.
  8. Pascal

    Pascal Senior Member

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    Unless in warm climates where you need air con no matter how much battery technology has progressed you still need to burn diesel to run air con
  9. Capt Ralph

    Capt Ralph Senior Member

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    Our ship is usually open while underway. Our inverter system works great at these times and a second alternator on out port main keeps the inverter bank up and in perfect shape.
    We have also witness a customers system run a wheel house A/C system this way.

    So were working to put together a 48v inverter system for another customer that could run his inverters and one or two A/Cs also.
    All the hardware and technology is out there except high amp 48v alternators.
  10. MBevins

    MBevins Senior Member

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    You are correct.
    We run pretty well everything except the AC off our Victron inverter/ Balmar Alt.
    Very rarely use the Gen unless we need ac or have been on the hook for the last couple of days.
  11. Capt Ralph

    Capt Ralph Senior Member

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    Sadly, Balmar stopped supporting 32 & 48v stuff long ago.
  12. MBevins

    MBevins Senior Member

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    That's unfortunate.
  13. Lepke

    Lepke Member

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    re: 48v alternator. Any alternator will do I use a GM CS-144 modified for 200 amps/12v (50 amps at 48V) output with a homemade regulator. GM-CS144s are very common, either new or used. There are rebuild kits for the bearings, etc., so they can last a long time. I got a couple extras as spares. Stock they're 140 amp. On ebay there's many for sale, about $2-300 for 200 amp and I saw a 250 amp for $225. (You do know alternators produce AC 3 phase high cycle power?)
    Before the regulator I used a rheostat to control the output. 50 amps is enough for me because I don't run AC. My area is the PNW to Alaska. But I do run a full double door reefer and 2 freezers, almost all my lights, windlass, heads (Incinolet), air compressor (air shifting & throttle) and anything else you might use in a house. I have run a 3300 watt water heater when I didn't want to run a generator. I have 3 banks of 4-8dc batteries. I went to 48v because I can have smaller cables, better choice in inverter and the batteries dispersed where the weight does the most good. At anchor, I've gone 3 days with 2 people on board w/o running out of power. The inverter has a kit that starts one of the generators if the voltage falls too low. I've only done that in testing. I save a couple gallons an hour not running a generator plus all the maintenance or rebuilds I don't do. Usually I run a generator for an hour every other day and make water at the same time. And I try to plan things like showers, laundry, hot water at that time so I have a decent load on the generator. My water heater is encased in 2" foam and all the lines insulated, so hot water will last a couple days and the galley has a 9 gallon that's left on.
    For more amps you can run a 48v alt on 2 engines or if you run at a steady rpm, an AC alternator. I have debated that because I cruise my Detroits at 1800 and that works for many generator ends w/o complicated drives. You can't run a high output alt with just belts. You need a serpentine or cog belt or a pto. There use to be a hydraulic driven AC generator that a lot of fishermen bought, but I haven't seen that advertised in a long time. It ran off a pump on the main engine and the rpm didn't matter because the motor ran at a constant speed. A good hydraulic shop could build one.

    http://www.markgrasser.com/products.htm#regulators - makes a 48v regulator I'm going to buy when the new one is out.
  14. cleanslate

    cleanslate Senior Member

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    Amazing! Very cool, I like this. BUT , It will take me a few days to process all of your , to me , technical information. My head is hurting. But I'm real good at painting and varnishing!...Lol
  15. cleanslate

    cleanslate Senior Member

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    Can you run, one at a time, a Microwave or electric range with this set up? Also my two refrigerators are 115volt AC only which are always on. Would it still work?
  16. Pascal

    Pascal Senior Member

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    Depends on the inverter and bank size.you need to do the math but i had set uo a Magnum 4000 with 12 golf cart batteries on a 70 i used to run. That would last 18 hours with 3 subzeros drawer sets, microwave, sat receivers, etc... recharged with generator in 5 hours

    What inverters are bad at running besides air con is any heating appliance like stove, oven, etc
  17. Lepke

    Lepke Member

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    I use a Magnum MS4448PAE that runs on 48v and puts out 4400 watts. It's rated to put out 6000 watts for 30 seconds, 5400 watts for 5 minutes (like starting a motor or compressor) . Up to 4 can be ganged for 16kw. I picked these because the ease of tying into the AC. It supplies 2-120v legs or 240. Everything runs thru the inverter. When shore power is cut it switches to battery. Your only limit is your battery bank. I run a reefer, freezers, microwave without thinking about it. You could run an electric stove, but you need a big battery bank. I'm in a cool climate and have a diesel stove.

    Attached Files:

  18. cleanslate

    cleanslate Senior Member

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    I think I'm gonna need a bigger boat! My 42' engine crawl space doesn't have the room for more batteries, along with the added weight, it won't work for me.
    I'm a weekend warrior with a 10 day trip thrown in once a year. So I think I'll continue to use my newly installed by me ,8kw generator and burn up some diesel and keep it simple/stupid.
    I love to put a heavy load on that thing as it was a P.I.A. to install, it's my way of getting back at it! Lol

    My next boat I hope to due more extended trips on, I would like to set up with batteries and inverters etc. as talked about on this thread.
    As always it was very insightful.