Full PLC Panels, Interface and Programming
We replaced the original failing PLC with a modern and reliable system. This provided an opportunity to add features and improvements in all areas. As a result the client obtained more control, information and automation when operating the vessel.
Complete new workshop built PLC drop in panels (into existing enclosure) and a new engine room enclosure were provided along with a new monitoring PC from Beckhoff. The two existing monitoring PCs (x2) were refurbished, upgraded and had a new windows OS installed.
Improvements were made in all areas to integrate communication from the main engine, generators (J1939 Canbus) and shorepower unit (ModbusTCP). The Victron battery and charger/inverter system was also integrated into the new setup. Running new rugged CAT7 PLC to I/O cables in a ring topology for full seamless redundancy whilst using Ethercat, in our opinion the absolute best protocol. This provides improved performance, reduced latency and higher reliability.
New PLC logic/code was developed for the project to control and monitor all hydraulics, tanks, sensors, machinery and much more. We made an improved power management system to protect the AC bus and allow easy automated control of the various power sources. With a lifting keel system from APM, with its locking pins and various sensors, we developed a few neat features including a backup control system, only accessible when the engineer logs in, to manually over-ride the logic interlocks and protections for maintenance and if one of the original sensors were to ever fail.
Another addition was the use of ECB’s, electronic circuit breakers which are user adjustable 1-8 Amp. These units offer significant space saving, undervoltage and overvoltage protection to their circuits and feedback/control of each breaker. The feedback and control allows us to monitor the breaker status in the event that an associated circuit outside of the panel were to be short circuited…the crew have a warning before the issue becomes a problem. The user can even remotely reset the breaker from the screen without having to open up the PLC panels (one of them being in the head liner area!).
Whilst the vessel is not required to adhere to classification society specification (Lloyds, DNV, RINA, etc…), the panels were built to class specification with all components being class type approved, including the new communication cables and panel wiring.
We worked with the client and crew to implement requests and deliver an interface with the desired color palette and aesthetics. This was fully custom solution, delivered on budget and on time. After commissioning the crew left Palma de Mallorca and had a busy season around the Mediterranean with lots of sea miles under sail, reporting no problems, improved interaction and extremely happy with the result.
