Upgrade of Propulsion & Manoeuvring Control Systems

Brunvoll has built a long history and legacy for propulsion and manoeuvring control systems, stretching back to the 1960s and across several production locations. Here is an overview of the available upgrade options. If needed, see also our separate pages on the Brunvoll Contol Legacy, and our retrofit options.

Overview of Control System Upgrade Options

Brunvoll has a longer history of control systems, from early 1960s till today. Therefore, we also offer several support, upgrade and retrofit options. Below is an overview of the more common, but please contact us for a solution fit your needs and your excisting systems.

Overview of the more common upgrade options include, and are detailed further below:

Brunvoll control system upgrade and retrofit options

Brunvoll Upgrade Conversion kit for Saia PCD4 and PCD2, to Saia PCD3
Neptun CPP upgrade to Neptun II
Neptun Compact upgrade to Triton or Neptun II
VERC (S5) to CPP@Control (S7) system
BruCon PTC retrofit - get the newest in Propulsion & Thruster Control
Dynamic Positioning & Joystick retrofit
Upgrade to full Condition Monitoring System

The options in bold type are detailed further in this article, while the others are found on other pages. An overview of Brunvoll control systems through the ages are found here: The Brunvoll Control Legacy

Some of these systems were delivered under the brand of Volda Mekaniske, Mar-El, or Scana, in addition to Brunvoll, so the logos and physical appearance for these systems might vary a bit.

For BruCon systems with Saia PCD4 or PCD2

Brunvoll used Saia PCD4 and PCD2 in our control systems since 1990 and up to around 2009. It was then replaced by Saia PCD3.
Earlier service letters have warned about the End of Life (EOL) for supported hardware, but Brunvoll have maintained a spares stock
Brunvoll now recommends either an upgrade to SAIA PCD3, or that you visit our webpages on retrofit options

BruCon Saia PCD3 PLC Upgrade Conversion Kit

All cabinets replaced by new cabinets of same size as old with new Saia PCD3 PLC based control system. New cabinets are equipped with touch screens for alarms/status/operation/configuration.
If ship cables are in good condition they can be re-used and no need for new cabling. All connections are arranged to fit existing cables/wiring/terminal details.
Pitch feedback is upgraded to a more accurate encoder type (2x4-20mA).
The bridge panels are upgraded, all internal signal handling according to 4-20mA and may be arranged according to original dimensions (cut-out). The new panels are equipped with a new lever type and new indicators which may be of combined type for indication of both thrust/load (Deif XDi). Push buttons for operation, lamps with LED for indication.
Size of panel, type of indicator, type of lever and layout for push buttons rely on customisations and arrangements found necessary for each installation.

Extra Options

Touch screen for alarms/monitoring in main panel or ECR (Will require extra cabling) as well as motorised levers may be supplied as options.

End Of Life for Saia PCD2 and PCD4 PLC spare parts

The conversion kit to Saia PCD3 offers a replacement of the existing PCD2 or PCD4 with only a very small modification of the control system. The replacement unit will fit the existing control cabinet. The replacement is done without any impact to the rest of the control system. Cabinets, wiring, cabling, panels, and sensors do not require replacement. The upgrade does not require any modification of the pitch feedback system.

The PCD3 PLC will be delivered according to existing system functionality, and operation of the system remains unchanged. The PCD3 PLC upgrade includes a new and improved software, and has the advantage of being supported hardware. The conversion kit is on stock at Brunvoll for fast delivery.

PCD4 and PCD2 PLC units have been obsoleted from Saia for some time, but Brunvoll has maintained a spares stock. The stock is now at a level where Brunvoll cannot guarantee future availability for PCD2 or PCD4 spare parts. We are now in a position that a replacement of the control system will be the only option. Brunvoll recommends upgrading of the control system to avoid future repair issues. There is no known EOL notification from Saia on PCD3.

Neptune CPP Control System

Older Neptune control systems can be upgraded by Brunvoll

Neptune CPP was available from 1999 to 2010.
Previous service letter from 2018 warned about that EOL for spare parts was set to 2020 with possible extension to 2025 if parts are available from sub-suppliers.
Today’s challenges with availability of electronic chips have made EOL of spare parts to Neptune systems a real issue that you should consider carefully.

Rebuilding from Neptune CPP to Neptune II control system

• Easy installation.

Using the same terminals and cabinets as Neptune CPP
Use of existing cables, except an ethernet cable from cabinet to ECR panel
Use of adapter frames on bridge panels to fit the existing cut-outs
Only approx. 3 days’ work on commissioning/sea trial together with an electrician onboard

• Additional advantages

Remote service connection
Possibility for several curves and modes
Alarm logging
High flexibility
Possibility for backup on levers, Hot backup
Spare parts available
Service engineers with great knowledge about the system
Short delivery time

Neptune Compact to Triton Upgrade

Older Neptune Compact systems can be upgraded to Triton or Neptune II control system.

Neptune Compact CPP control system was available from 2003 to 2013.
We aim to deliver spare parts to 2024, with a possible extension to 2025, if components are available from sub-suppliers.
Today’s challenges with availability of electronic chips have made EOL of spare parts to Neptune Compact systems a real issue that you should consider carefully.

Rebuilding from Neptune Compact CPP to Neptune II, or Triton CPP control system

• Easy installation.

Using the same terminals and cabinets as Neptune Compact CPP
Use of existing cables, additional wiring for panel communication required.
Use of adapter frames on bridge panels to fit the existing cut-outs.
Only approx. 2-3 days work on commissioning/sea trial together with an electrician onboard

• Additional advantages

Remote service connection
Possibility for several curves and modes
Alarm logging
High flexibility
Short delivery time

Upgrade of VERC Siemens S5 PLC

The VERC control system was supplied from 1993 to 2002
VERC was based on the Siemens Simatic S5 controller, which is no longer supported

The upgrade option we deliver is a Siemens S7 PLC, which replace the S5 PLC in the older control systems. By using the existing hardware in the controller cabinet and combining this with a newer PLC we are able to offer a simple to install solution at a reasonable price. The Siemens S7 PLC is still in stock in foreseeable future.

The upgraded system comes complete with a touch screen operator panel that allows the engineers on board to adjust the settings of the system and read the internal alarm history of the remote control system.

Another advantage when upgrading is that the remote control systems will be programmed to comply with existing class requirements with regards to monitoring and failure states (FMEA requirements). Further upgrades such as operation modes, alarms, monitoring, PTH (“take me home”) and so on can also be implemented.