Installation Instructions for DEIF PPM-3



Installation Instructions for DEIF PPM-3

Basic Information

Product subject: DEIF PPM-3 protection and power management controller, belonging to the Multi line 2 series, mainly aimed at ship power systems, supporting control of five major power units: diesel generators (DG), emergency generators (EDG), shaft generators (SG), shore power (SC), and bus tie switches (BTB).

Target audience: Cabinet design and installation engineers; Core uses: equipment installation, terminal wiring, hardware configuration, communication wiring, safety operation guidance.

Core coverage areas: safety specifications, installation dimensions, hardware card slots, definition of five types of unit I/O terminals, all types of wiring, hardware technical parameters.

General Information (Security, Instructions, Factory Settings)

1.1 Safety, Legal and Static Electricity Regulations

Identification differentiation

Warning: Violation may result in personal injury or equipment damage;

Note: Auxiliary practical tips.

Disclaimer

DEIF is not responsible for the installation/commissioning of the unit; Unauthorized opening of the lid directly results in loss of warranty; Document updates will not be notified separately. The original English version is authoritative, and the translated version is for reference only.

Electrical safety

Only certified electricians are allowed to operate the equipment. There are dangerous AC and DC voltages present, and touching the AC measurement terminals is prohibited to prevent electric shock and death.

Static Electricity Protection (ESD)

Static electricity must be prevented when installing terminals; After the wiring of the entire machine is completed, no protection is required.

factory parameters

The controller is pre-set with a universal mean parameter, and the matching must be rechecked before the unit is put into operation.

1.2 Manual Instructions for Use

Purpose: To provide a complete set of installation materials for hardware, installation, terminals, and wiring, which must be read thoroughly before installation;

Applicable personnel: cabinet designers, on-site installation personnel;

Layout rules: Each chapter starts independently and has a clear structure for easy reference.

Installation Specifications (Cabinet Openings, Torque, Dimensions)

2.1 Installation method and size

Installation scenario: Installation inside the ship control cabinet; The display screen can be separated into cabinet doors and connected to the host through dedicated cables; Standard configuration includes 6 screw positions for fixation, and the manufacturer recommends tightening the screws for installation. It is prohibited for grease or cutting oil to come into contact with the plastic shell (damage and loss of warranty).

Dimensional parameters (mm/inch): The length, width, and thickness of the host, display screen, and AOP operation panel are fully labeled;

Cabinet door opening:

Minimum installation space: 222 × 115mm;

Sealing gasket frame: 186 × 77mm;

Fixed screw: 3.5mm self tapping screw, maximum screwing depth of 9mm;

Matching millimeter/inch dual-purpose drilling template.

2.2 Tightening torque (key installation standard)

Torque conversion for installation location

Host base fixed 0.3 Nm (2.7 lb in)

Terminal plug 0.5 Nm (4.4 lb in)

Cabinet door display screen 0.7 Nm (6.2 lb in)

9-pin Sub-D communication head 0.2 Nm (1.8 lb in)

DC-DC converter terminal 0.5 Nm (4.4 lb in)

Overall Hardware Architecture (8 card slots Slot1-8)

The controller is composed of 8 pluggable PCB boards, matched with green terminals, distinguishing between standard boards and optional expansion boards. The slot functions are uniformly adapted to DG/EDG/SG/SC/BTB five types of units. Slot overview:

Slot1 (standard): power board, terminals 1-28, DC power supply, basic relay, digital input;

Slot2 (optional): Communication board H2 Modbus, H3 Profibus, H8.2 CAN external IO, terminals 29-36;

Slot3 (standard): Load sharing, universal digital input/output, terminals 37-64;

Slot4 (standard optional): Governor GOV/Voltage Regulating AVR output, standard relay, optional E1/E2/EF analog output; DG equipped, SG/SC/BTB does not have this board;

Slot5 (standard): Three phase voltage/current AC measurement board, terminals 73-89;

Slot6 (optional): Analog output, multiple digital inputs/relays, 4-20mA analog input (F1/M13.6/M14.6/M15.6);

Slot7 (standard): Engine interface board, speed MPU, multifunctional input, start stop relay, dual redundant CAN bus;

Slot8 (optional): Engine CAN communication H5/H8.8, extended IO module (M13.8/M14.8/M15.8).

The board is divided into two categories: hardware selection (physical board) and software selection (PC software activation, no hardware changes).

Definition of I/O Terminals for the Five Major Power Units (Core Wiring Chapter)

The hardware layout framework of the five types of unit slots is unified, but the terminal functions are differentiated according to the device's purpose, divided into two main modules: digital input and relay output

General board basic functions (shared hardware base for five types of units)

Slot1 power board (terminals 1-28)

Power supply: 1/2 terminal 8-36VDC (12/24V system), circuit equipped with 2A slow melting fuse;

Status relay (3/4): normally closed, monitoring main control and power failure;

Universal relay: alarm horn, circuit breaker opening/closing, programmable contacts, rated 250VAC 8A;

Transistor collector output (20/21): low-power programmable passive output;

Optocoupler digital input: local manual operation, circuit breaker opening and closing feedback, programmable switch quantity, common terminal 28.

Slot2 external communication terminal (29~36)

H2 Modbus RTU: RS485 A/B dual line, both ends need to be matched with terminal resistors;

H3 Profibus DP: Corresponding to 9-pin Sub-D bus pins;

H8.2 CAN bus: External IO expansion CAN-H/GND/CAN-L dual line group.

Slot3 Load Sharing and Switching Values (37-64)

Analog equalization signal: active ± 5V, reactive ± 5V;

Given analog input: frequency/voltage ± 10V passive given;

Optocoupler DI: manual voltage and speed regulation, overload request, short circuit alarm, alarm shielding;

Relay output: Heavy load allowed, non critical load NEL opening 1/2.

Slot5 three-phase AC measurement (73~89)

Current circuit: CT secondary 1/5A, three-phase L1/L2/L3, electrically isolated, 0.3VA per phase;

Voltage circuit: Generator voltage, bus voltage, phase to phase 100-690V, land system supports neutral N, ships generally do not connect neutral wire.

Slot7 engine interface board (98~124, standard for all generators)

Secondary power supply 98/99:8~36VDC;

MPU magnetic pulse speed input 100/101: 0.5~70VAC, 10~10000Hz;

Three channel multifunctional input (102/105/108): default wire breakage detection DI, switchable between 4~20mA, Pt100/1000, 0~40V, and resistance RMI;

Programmable digital input: remote start stop, allow start, run feedback, emergency stop;

DC relay output (24VDC 5A): operating coil, pre lubrication preheating, starting motor, stopping coil (with wire breakage monitoring);

Dual redundant CAN bus A and B: power management communication between units, J1939 engine communication (H7 optional).

Differentiated terminal functions for five types of units

Chapter 4 DG Diesel Generator

Unique GOV/AVR speed and voltage regulating relay output (Slot4); Terminal differentiation generator circuit breaker GB; supports heavy-duty HC logic; Equipped with two outputs of mechanical/electronic speed regulation.

Chapter 5 EDG Emergency Generator

Increase the TB opening and closing output/feedback of the bus tie circuit breaker; Add dock mode input (automatic disconnection of busbars in parallel for 30 seconds), main busbar electrical detection DI; other generator interfaces are the same as DG.

Chapter 6 SG Shaft Generator

Slot4 vacant without adjustable speed pressure plate; No engine start circuit, all start stop and speed related terminals are programmable; Only retain load sharing and circuit breaker SGB logic.

Chapter 7: SC Shore Power Unit

No engine interface such as MPU, start stop coil, etc; Only shore power circuit breaker SCB control, all engine related terminals are universal programmable DI/DO.

Chapter 8 BTB Bus Union Switch

Measurement of three-phase voltage for dual bus A and B channels; No power generation/engine hardware, only responsible for the connection and disconnection of two bus sections, short-circuit protection, and load unloading.

Supporting expansion optional board (Slot6/Slot8)

M13. x.7: 7-way passive digital input;

M14. x: 4-channel AC250V 8A programmable relay;

M15. x: 4-channel 4-20mA analog acquisition;

F1: Two 4 (0)~20mA transmission outputs;

H5/H8.8: CAN bus expansion engine/external IO;

E1/E2/EF4/EF5: GOV/AVR analog/pulse/PWM speed and voltage regulation output.

Specification for All Types of Wiring (Core of Wiring Practice)

9.1 Wiring for three-phase AC measurement

Distinguish between DG/EDG/SG shore power and BTB dual bus connection methods; CT secondary is strictly prohibited from open circuit, neutral wire is not necessary, transformer S1/S2 can be grounded arbitrarily, and AC circuit is equipped with 2A slow melting fuse.

9.2 Internal CAN bus (inter unit communication)

Dual line CAN-H/CAN-L+shielded ground, with 120 Ω terminal resistors at both ends;

The maximum bus length is 200m, and CAN fiber optic converters are used for distances exceeding 200m;

A. Dual CAN redundancy is used in parallel.

9.3 Wiring of various communication buses

Modbus RTU (H2): Shielded twisted pair, shielded single ended grounding, long link circuit bias resistor;

Profibus DP (H3): Standard DP shielded cable;

Engine CAN (H5/H7): 120 Ω terminal resistance, shielded single ended grounding;

Display cable (J): 9-pin Sub-D, maximum length 6m, wire diameter ≥ 0.22mm ².

9.4 Load Classification Ratio Cable (G3)

± 5V analog signal, shielded twisted pair, unit spacing ≤ 3m.

9.5 Wiring of speed and voltage regulating actuators

Mechanical speed controller (standard relay output): DC coil in reverse parallel with 1N4007 freewheeling diode, AC with varistor;

Electronic speed regulation/analog AVR: ± 20mA analog output, 250 Ω resistor can be converted to ± 5V; optional D supports analog voltage regulation;

EF series hybrid output: simultaneously providing relay+analog/PWM signals, speed and voltage regulation with either one multiplexed hardware channel.

9.6 Wiring of Switching Values and Analog Sensors

Ordinary binary DI: bidirectional optocoupler 12/24V DC;

Wire breakage detection DI: circuit string 270 Ω standard resistor;

Multi functional input: supports two-wire/three wire Pt100, 4-20mA active/passive transmitters, resistance signals;

M15 analog input: Passive 4-20mA acquisition, requires external 24V power supply;

Transistor output (OC): Low power, external relay/counter requires freewheeling diode.

9.7 Special Requirements for Shutdown Coil

The shutdown circuit with wire breakage monitoring must be connected in parallel with the terminal of the freewheeling diode protection controller.

General Technical Specifications (Machine Parameters)

1. Accuracy and Environment

Measurement accuracy level 1.0, analog output EF series level 4.0;

Working temperature: -25~70 ℃, UL certified maximum 55 ℃; Storage -40~70 ℃;

Altitude: ≤ 2000m full range, used for voltage reduction from 2000 to 4000m;

Protection: Host IP20, standard display screen IP40, optional sealing gasket IP54;

Vibration/Shock: Meets IEC Ship IACS UR E10 Marine Standard.

2. Electrical Rating

Power supply: 8-36VDC, maximum 11W for the whole machine, 5W for the engine board, 10ms continuous power supply after starting voltage drop, 2A slow melting fuse;

Communication measurement: voltage 100~690VAC, CT 1/5A; Short term overload 80 times rated for 1 second; Frequency range of 30~70Hz;

Switching quantity: DI conducts 8-36VDC, disconnects<2V; relay 250VAC 8A, UL certified resistive 2A; OC output maximum 10mA;

Analog channel: Output 0/4~20mA, ± 20/25mA, load ≤ 500 Ω, electrical isolation; Average signal ± 5V;

Response speed: Short circuit, reverse power, undervoltage protection<250ms, emergency stop<200ms, overspeed<500ms.

3. Compliance and Machinery

Safety standards EN61010, UL508, EMC meets industrial/marine zoning standards;

Installation: Two methods: guide rail/screw base; The weight of the host is 1.6kg, and the display screen is 0.4kg;

Cable specifications: differentiate between AC, DC, and communication cable diameter specifications, UL equipment only allows 60/75 ℃ copper wires.