Modular Architecture Analysis of DEIF PPU 300 Ship Generator Controller

Modular Architecture and Engineering Application of DEIF PPU 300 Ship Generator Controller

In the fields of ship power systems, marine engineering platforms, and special vessels, the reliability, flexibility, and maintainability of generator controllers are directly related to navigation safety and operational efficiency. The PPU 300 launched by DEIF is a configurable controller designed specifically for the shipbuilding industry, covering various control scenarios such as generators, hybrid power, shaft generators, shore power connections, and bus tie circuit breakers. Its modular hardware architecture, powerful communication capabilities, and intuitive graphical display interface provide highly flexible solutions for ship electrical engineers. This article is based on the PPU 300 product manual, systematically analyzing its hardware composition, core functions, protection configuration, software tools, and engineering application points, providing comprehensive technical references for ship power system design and operation personnel.

Product positioning and controller type

PPU 300 is a configurable controller for the shipbuilding industry, featuring a modular design that allows users to flexibly replace or add hardware modules according to their application needs. The system supports CODESYS as an additional feature, which can be extended with custom logic to meet special control requirements. The accompanying PICUS software is a free PC tool that supports single line diagram drawing, parameter configuration, system simulation, permission management, backup, and firmware upgrade, greatly simplifying the engineering design and debugging process.

Controllers are divided into five types, each targeting specific application scenarios:

GENSET controller: controls and protects the engine, generator, and generator circuit breaker, and is the core unit of ship power stations.

HYBRID controller: controls and protects inverters and inverter circuit breakers with power supply, suitable for hybrid propulsion systems.

SHAFT generator controller: controls and protects the shaft generator system, commonly used in situations where the main shaft power is used for power generation.

SHORE connection controller: controls and protects shore power connections and shore power circuit breakers, and manages shore power access when ships dock.

BUS TIE bus tie controller: Each bus tie circuit breaker is equipped with a controller for bus section management.

The controller adopts a 5-inch high-resolution color graphic display screen with physical buttons, supports multiple languages, can display real-time status information, measurement data, and alarm information, and can directly change the controller mode, operate circuit breakers, and start stop units through the display screen.

Modular hardware architecture

The hardware system of PPU 300 is based on an aluminum rack, in which replaceable printed circuit board modules are installed. High speed communication between modules is achieved through rack backboards to achieve real-time data exchange. The system offers two rack sizes:

Rack 4.1 (large rack): includes PSM3.1 power module and blind board, can accommodate 7 hardware modules, size 230.1 × 199.9 × 139.3mm.

Rack 4.1 (small rack): includes PSM3.1 power module and blind board, can accommodate 4 hardware modules, size 146.1 × 199.9 × 139.3mm.

Each rack is equipped with cable stress relief plates and cable tie slots for easy wiring management.

Core hardware module

PSM3.1/PSM3.2 power module: 12V or 24V DC power supply, providing power for the entire rack.

ACM3.1 AC module: used to measure circuit breaker current and voltage, supports up to 690V AC direct input, with an accuracy of Class 0.5.

ACM3.2 differential current module: specifically designed for measuring differential current in generators, supporting stable differential (87G) and high setting differential protection.

IOM3.1 I/O module: 4 relay outputs+10 configurable digital inputs.

IOM3.2 I/O module: 4 relay outputs+4 multifunctional analog outputs (including 2 PWM channels)+4 digital inputs+4 multifunctional analog inputs.

IOM3.3 I/O module: 10 multifunctional analog inputs (configurable).

IOM3.4 I/O module: 12 transistor outputs+16 digital inputs.

GAM3.1 speed/voltage regulation module: 4 relay outputs+2 analog outputs+1 PWM output+2 analog inputs.

GAM3.2 speed/voltage regulation module (built-in power supply): 2 analog outputs+1 PWM output+1 status relay output+4 relay outputs+5 digital inputs.

EIM3.1 engine interface module (built-in power supply): 4 relay outputs+1 speed input+4 digital inputs+3 analog inputs. This module can serve as a safety shutdown module, allowing the engine to operate independently even when unable to communicate with the main processor.

PCM3.1 processor and communication module: the system core responsible for logical operations and communication management.

Plug and play feature: The system supports automatic recognition and configuration of modules, and can restore functions without manual intervention after module replacement, greatly reducing maintenance complexity.

PICUS software and CODESYS extension