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

PICUS tool

PICUS is a free PC software provided by DEIF, with features including:

Single line diagram drawing: graphic design of system topology.

Parameter configuration: Set controller parameters, I/O functions, and set value groups (up to 4 sets of rated parameters).

System simulation and monitoring: Logic can be verified without the need for hardware.

Permission management: Delegate power according to users/user groups.

Backup and firmware upgrade: a convenient maintenance tool.

Trend recording: Real time tracking of changes in measurement values.

CODESYS extension

Users can order CODESYS as an additional feature to achieve:

Custom logic programming (compliant with IEC 61131-3 standard).

Increase the number of controller functions (up to 20 Modbus signals per controller, which can be mapped as inputs or outputs).

Combining with Flexible Modbus to expand communication capabilities.

Protection function (ANSI standard)

PPU 300 provides comprehensive source side (generator/inverter/shaft/shore power) and bus side protection, all of which are based on high-speed processors and internal communication for fast action. The following is a list of protection functions (ANSI numbers in parentheses):

Source side AC protection

Protection function ANSI level

Overvoltage 59 2 segments

Undervoltage 27, Section 2

Voltage imbalance 47 1 segment

Negative sequence voltage 47 1 segment

Zero sequence voltage 59N, segment 1

Overcurrent (timed limit) 51 2 segments

Quick break overcurrent (short circuit) 50/51 2 segments

Current imbalance 46 2 segments

Inverse time overcurrent 51 1 segment

Directional overcurrent 67 2 segments

Negative sequence current 46 1 segment

Zero sequence current 51N, segment 1

Over frequency 81O 2 segments

Underfrequency 81U 2-segment

Overload 32 2 sections

Reverse power 32R 2 segments

Overexcitation (reactive power output) 400 2 segments

Underexcitation (reactive input/demagnetization) 40U 2-stage

Stable differential current protection 87G 1st section (ACM3.2 required)

High setting differential current protection 87G 1st section (ACM3.2 required)

Synchronization check (including black start closing) 25 1 section

Bus side AC protection

Protection function ANSI level

Overvoltage 59 2 segments

Undervoltage 27, Section 2

Voltage imbalance 47 1 segment

Over frequency 81O 2 segments

Underfrequency 81U 2-segment

Other AC protections

Locking relay (86)

Grounding inverse time overcurrent (51G)

Neutral point inverse time overcurrent (51N)

All protections have definite time characteristics, flexible settings, and can meet the requirements of classification societies and power grid regulations.

Communication and Network

The communication capability of PPU 300 is one of its core advantages:

5 RJ45 Ethernet ports: Supports IPv6 (auto configuration) and IPv4 (configurable), allowing access to all controllers within the network through a single Ethernet connection.

DEIF network: Ring network communication between controllers, providing communication redundancy. Support load distribution, synchronization/load shedding, external bus coupling position feedback, and automatic detection of bus segments (including ring buses).

CAN bus: used to connect the engine ECU (supporting the universal J1939 protocol), read engine parameters, and control the ECU.

Modbus: Supports multiple Modbus protocols, configurable server settings, supports data unit conversion and scaling.

Authentication and Security: Network communication has authentication mechanisms to prevent external device interference; Support password protection (customizable permission levels).

NTP time synchronization: The controller in the system automatically synchronizes the date/time and can also synchronize with the NTP server.

Display Unit DU300

DU300 is a 5-inch high-resolution color graphic display screen with dimensions of 238 × 178 × 52.4mm. Its features include:

Intuitive menu navigation and help information make it easy for operators to quickly get started.

Physical buttons are easy to operate in harsh environments (gloves can also be worn).

Supports multiple languages.

Each controller can connect up to 2 display units (with interlock function).

The screen can display status information, real-time measurement values, alarm lists, and event logs.

Key Additional Features

AC Measurement Averaging: In response to numerical fluctuations caused by high measurement accuracy, 200ms or 800ms averaging filters can be applied to measurement values such as voltage, current, and frequency. The filtered data is used for display, trend recording, Customs Logic, CODESYS, and Modbus, but it does not affect the protection criteria and adjustment values, ensuring that the protection speed is not affected.

Engine Interface Safe Shutdown (EIM3.1): The EIM3.1 module can be configured as a safe shutdown module, which can safely shut down the engine in independent mode even if communication with the main processor is interrupted, providing hardware level safety redundancy.

Flexible configuration of relays and analog signals:

The relay can be configured with functions and coil status (normally open/normally closed).

Analog input supports sensor fault detection (below lower limit and above upper limit).

Provide pre configured curves and up to 20 custom curves.

Analog output also supports up to 20 custom curves.

Circuit breaker control: Supports pulse, compact, and continuous circuit breakers, providing synchronous (dynamic/static), black start closing, load shedding, and circuit breaker position detection and alarm. Redundant circuit breaker feedback improves reliability.

Control mode: Supports three modes: local, remote, and distribution panel control, suitable for different operating scenarios.

Summary of Technical Specifications

Electrical safety

EN 61010‑1，CAT III，600V， Pollution level 2

IEC/EN 60255‑27，CAT III，600V， Pollution level 2

UL508，UL6200，CSA C22.2 No.14‑13，CSA C22.2 No.142 M1987

Electromagnetic Compatibility (EMC)

EN 61000-6-3 (Residential, Commercial, and Light Industrial)

EN 61000-6-2 (Industrial Environment)

IEC/EN 60255-26, IEC 60533 (Distribution Areas), IACS UR E10

IEC 60945 (Display Unit)

ISO 7637-2 pulse 5a (sudden load drop)

environment

Working temperature: Rack and module -40~70 ℃, display unit -20~70 ℃ (UL certification limit of 55 ℃)

Storage temperature: Rack and module -40~80 ℃, display unit -30~80 ℃

Humidity: 97% RH (IEC 60068-2-30)

Working altitude: 0~4000m (derating is required above 2000m, see module specification)

machine

Vibration (operation): 3~8Hz 17mm peak to peak value, 8~100Hz 4g, 100~500Hz 2g

Vibration (response): 0.15mm peak to peak at 10~58.1Hz, 1g at 58.1~150Hz

Vibration (durability): 58-150Hz 2g

Earthquake: 3~8.15Hz 15mm peak to peak, 8.15~35Hz 2g

Impact (base installation): 10g/11ms (response), 30g/11ms (durability), 50g/11ms (IEC 60068-2-27)

Collision: 20g/16ms (IEC 60255-21-2 Class 2)

Material: UL94 V0 self extinguishing

Certification

CE，UL/cUL Listed（UL508，CSA C22.2 No.142），UL/cUL Recognised（UL6200，CSA C22.2 No.14‑13）

Certification by major classification societies (latest list available at www.deif. com)

Engineering Application and Maintenance Suggestions

Rack selection: Choose a large rack (7 slots) or a small rack (4 slots) based on the number of I/O points, protection functions, and communication requirements, and reserve at least one empty slot for later expansion.

Module configuration: Generator protection comes standard with ACM3.1 and PCM3.1; If differential protection is required, add ACM3.2; If a safe shutdown function is required, use EIM3.1 and configure independent shutdown logic.

Network design: using ring network topology to achieve communication redundancy; All controllers can be accessed through a single Ethernet portal, simplifying SCADA integration.

Software backup: After debugging, backup the complete parameters and I/O configuration through PICUS and save them to a safe location.

Firmware upgrade: Upgrade the controller and display unit firmware through PICUS, and confirm compatibility before upgrading.

Permission management: Configure multi-level password protection, distinguish operator, engineer, and administrator permissions, and prevent misoperation.