Subsea Pitch Control Panel Build for a Marine Renewables OEM
Sector:
Renewable Energy, OEM & Special Purpose Machinery
Type:
New Build - Control System
Platform:
Beckhoff
Certification:
CE / UKCA
Summary
DelaControl designed and built a replacement control cabinet for a marine renewables OEM, intended for subsea installation. The scope included structural design improvements to address identified failure modes, full hardware build and test, mechanical manufacturing drawings, and a Factory Acceptance Test.
Challenge
An existing pitch control cabinet deployed in a subsea environment had failed in service. The root cause could not be confirmed until the panel was retrieved from its operating location, but investigation had identified a number of probable design weaknesses.
These included concerns around the structural integrity of the backplate and its mounting, the backplate mounted on the inside face of the door, the mounting and wiring of bulkhead connectors, and the method of securing the panel to its final installation point. The working theory was that a loose backplate had damaged internal connectors or caused components to shake free from the DIN rail. The customer needed a replacement panel built to a higher structural standard, with the known design flaws designed out and any further weaknesses identified and addressed.
Solution
DelaControl produced mechanical manufacturing drawings from 3D step models of both the existing and revised enclosure concepts, incorporating the structural improvements required. This included design changes to the backplate mounting, bulkhead connector arrangement, and panel fixing, drawing on experience from comparable demanding projects. Structural analysis was not within scope; DelaControl applied best practice engineering judgement to the detail design.
All panel components were procured and supplied by DelaControl, with Beckhoff automation hardware and Nidec pitch smart control drives provided as free-issue items by the customer. The Rittal enclosure was finished in RAL 7035, with Weidmueller terminals and Phoenix Contact protective and feed-through terminal blocks throughout. Harting heavy-duty connectors were used for the bulkhead interfaces, and the EtherCAT communications architecture was realised using Beckhoff EtherCAT Box modules and associated cabling.
Documentation delivered included mechanical manufacturing drawings, a Declaration of Conformity (LVD and EMC), an Inspection and Test Schedule and FAT Certificate, thermal calculations using Rittal Therm software, and a SISTEMA report (ISO 13849-1) identifying the achieved PLr rating for the safety functions. Pre-delivery testing used I/O simulation test boxes and test motors to verify electrical correctness and functional operation. The customer was invited to a Factory Acceptance Test at DelaControl's Bristol facility prior to delivery.
Key Facts
• Beckhoff EtherCAT Box remote I/O platform (EP and EM series modules)
• Beckhoff EtherCAT Box modules include: 4-ch analogue input RTD (EP32040002), 8-ch digital input ×2 (EP10080001), IO-Link master ×2 (EP62240002), power distribution with current measurement ×3 (EP92240023), media converter (EP95210020)
• Pilz PNOZsigma safety relays (PNOZ s2) used for safety functions
• Harting Han heavy-duty connectors used throughout for bulkhead interfaces
• MOXA Smart 2-Port Ethernet switches ×2
• Phoenix Contact Type 2 surge arresters and LAN CAT.6A surge protection included
• 3-phase RFI line filters (Block HLD110) fitted
• SISTEMA report (ISO 13849-1) produced to establish achieved PLr rating
• Thermal calculations performed using Rittal Therm software
• Factory Acceptance Test conducted at DelaControl's Bristol facility
• 7–8 week lead time from order placement