ICP DAS provides a comprehensive monitoring solution for damage control and vessel safety systems, offering reliable surveillance of critical areas such as fire detection, compartment flooding, and passageway security. By supporting CAN Bus architecture, multiple communication protocols, and robust data acquisition and transmission capabilities, the solution significantly enhances vessel safety and operational efficiency.

Introduction:

During navigation, vessels must be equipped with comprehensive damage control and onboard safety systems to ensure the safety of both the vessel and crew. The damage control system monitors potential risks that could lead to sinking, such as compartment flooding, temperature anomalies, and pipeline pressure. In the event of an emergency, it can initiate corresponding responses, such as activating drainage systems and fire pumps. The onboard safety system, on the other hand, is responsible for monitoring the status of onboard equipment, fire alarms, and emergency doors.

To improve vessel safety, the customer sought to upgrade their existing onboard safety and damage control systems. However, the vessel’s system architecture was highly complex, involving multiple subsystems such as fire detection, compartment flooding monitoring, and generator set management. Ensuring smooth data exchange between these disparate systems and achieving centralized management presented a major challenge. In response, ICP DAS provided highly compatible and stable controllers, I/O modules, and gateways to help the customer build a more reliable vessel safety and damage control system. The following section outlines the solution in detail.

Smart Integration of Vessel Safety Systems for Comprehensive Real-Time Monitoring

The system architecture consists of two main parts: the Damage Control System and the Vessel Safety System.

1. Damage Control System (DCS) The customer required a dual-CAN Bus architecture to ensure the continuous transmission of critical data, even in the event of a single-channel failure. A custom proprietary communication protocol developed by the customer is used. The system primarily collects signals related to compartment flooding, temperature, and pipeline pressure via data acquisition boxes. These signals are transmitted through the proprietary CAN protocol and integrated into the DCS host computer. The host then interfaces with the control box to execute actions such as activating drainage systems, fire pumps, bottom valves, and remotely shutting down ventilation fans.

• Dual-CAN Bus Architecture

The system adopts a dual-CAN Bus architecture. ICP DAS’s LP-8821 and LP-8421 Linux-based controllers are used in the data acquisition and control box subsystems, respectively. Each controller is equipped with the I-8120W 1-port CAN Programmable Module, enabling CAN Bus communication capabilities. This setup allows the controllers to exchange data with the damage control system’s monitoring platform via CAN Bus.

The I-8120W is a standalone CAN Bus Programmable Module designed to integrate seamlessly with ICP DAS’s Programmable Automation Controller (PAC) series. It allows the main controller to transmit and receive CAN Bus messages without adding load to the CPU. When combined with the PAC’s rich communication interfaces—such as RS-232, RS-485, and Ethernet—the I-8120W functions as a fully programmable device controller. This solution has been widely adopted in a variety of CAN Bus system applications.

• Data Monitoring via the Data Acquisition Box

In addition to the I-8120W module, the customer also selected the I-87053W 16-channel Isolated Digital Input Module and the I-87017RCW 8-channel Current Input Module to collect data related to compartment flooding, temperature, and pipeline pressure. This data is transmitted by the LP-8821 Linux-based Controller using the customer’s proprietary CAN protocol to the host computer of the DCS for centralized integration.

The I-87053W 16-channel Isolated Digital Input Module features a low-pass filter for electrical noise suppression and a dual-watchdog mechanism. Each channel includes photocoupler isolation and an LED indicator, and can be independently configured. The digital input channels can also be used as 16-bit counters.

The I-87017RCW 8-channel Current Input Module features built-in resistors, enabling direct current measurement and significantly reducing measurement costs. It supports two sampling modes: normal mode and high-speed mode. Each channel can be independently configured with selectable input ranges, including 0 to +20 mA, +4 to +20 mA, and -20 to +20 mA.

The LP-8821 is a Linux-based PAC featuring a Cortex-A8 CPU and running on the Linux 3.x kernel. It supports various communication interfaces, including VGA, USB, Ethernet, and RS-232/485. Equipped with eight I/O expansion slots, it is compatible with ICP DAS’s I-8KW and I-87KW series I/O modules for efficient data acquisition.

• Data Monitoring of the Control Box

In addition to the I-8120W module, ICP DAS also installed the I-87061PW 16-channel Power Relay Output Module to receive control commands from the host computer of the DCS and trigger contact switching. Furthermore, the local LP-8421 Linux-based controller uses the Modbus TCP communication protocol to retrieve data from the acquisition box, including compartment flooding status, temperature readings, and pressure signals. It then executes basic local logic control functions—such as activating drainage systems, starting fire pumps, and remotely controlling ventilation units—to ensure proper operation, even if the host computer fails to respond.

Each relay output channel of the I-87061PW 16-channel Power Relay Output Module is independently controlled, with no shared COM point between channels. The module supports the DCON communication protocol and features a dual watchdog timer, along with configurable power-on values and safe value output settings.

2. Vessel Safety System (VSS) The vessel safety system utilizes ICP DAS’s LP-8421 Linux-based controller and is designed to integrate four functional areas:

• Acquisition of digital I/O and analog input signals related to equipment electrical status and fire alarms

• Monitoring the status of passageway and compartment safety doors

• Monitoring the status of RS-485-connected equipment, such as generator sets

• Integration with the vessel safety system’s host computer

• Acquisition of Digital Input/Output and Analog Input Signals for Equipment Electrical Status and Fire Alarms

ICP DAS assisted the customer in deploying the ET-87P8-MTCP 8-slot Intelligent Ethernet I/O Expansion Unit, along with I-87KW series I/O modules — including the I-87053W 16-channel Isolated Digital Input Module, I-87057W 16-channel Isolated Digital Output Module, and I-87017RCW 8-channel Current Input Module. In addition, the ET-7260 Ethernet I/O Module was installed to collect various equipment status signals, such as contact points, indicator lights, alarms, door/window limit switches, emergency switches, and fire alarm contact signals.

These signals are distributed across a wide area — from the deck to the lower compartments — with a total of seven ET-87P8-MTCP units deployed throughout the vessel. Both the ET-87P8-MTCP and ET-7260 transmit data to the LP-8421 controller via the Modbus TCP protocol.

The ET-87P8-MTCP 8-slot Intelligent Ethernet I/O Expansion Unit is a Modbus TCP I/O expansion device equipped with eight I/O slots. It supports the expansion of ICP DAS’s I-87KW series I/O modules over Ethernet, making it suitable for a wide range of industrial monitoring applications. The ET-87P8-MTCP features two Ethernet ports, enabling daisy-chain topology that allows multiple ET-87P8-MTCP units or other Ethernet devices to be connected in series — simplifying centralized wiring. In addition to supporting Modbus TCP and Modbus RTU/ASCII communication protocols, the ET-87P8-MTCP also offers Modbus TCP-to-RTU gateway functionality for seamless integration across different Modbus networks.

The I-87057W 16-channel Isolated Digital Output Module provides protection against over-voltage, overload, and short-circuit conditions. It also allows users to configure Power-On Values and Safe Values for added safety. Each channel supports up to 100 mA load current, is equipped with optocoupler isolation, and features 4 kV ESD protection as well as 3750 Vrms intra-module isolation, offering strong resistance to electrical noise interference in industrial environments. Additionally, each output channel includes a dedicated LED indicator to clearly show the current output status.

The ET-7260 Ethernet I/O Module integrates a 2-port Ethernet switch, 6 digital input channels, and 6 power relay output channels.

• Status Monitoring of Passageway and Compartment Safety Doors

For critical areas such as passageway and compartment safety doors, the customer required signal transmission via the CANopen protocol. To meet this need, the I-8123W 1-Port High-Performance Intelligent CANopen Master Module was deployed, along with the CAN-2057C 16-channel Isolated Digital Input Module (CANopen slave), and the CAN-8423 Remote I/O Unit with 4 I/O Slots (CANopen slave) paired with I-87KW series I/O modules for acquiring contact signals from the safety doors.

The I-8123W 1-Port High-Performance Intelligent CANopen Master Module provides communication capabilities for CANopen slave devices. It features a dedicated CAN Bus communication port that supports a wide range of CANopen applications. The I-8123W is compatible with ICP DAS’s PAC series controllers and is widely used in fields such as industrial automation, building automation, transportation, marine equipment, and embedded control systems.

The CAN-2057C is a 16-channel isolated digital output module (CANopen slave) featuring open-collector (sink-type) outputs on all channels. It can be used in various system architectures, such as driving relays or connecting resistive loads. When paired with a CANopen master from ICP DAS or other vendors, users can quickly build a CANopen network tailored to their application needs.

The CAN-8423 Remote I/O Unit with 4 I/O slots (CANopen slave) is designed specifically for use with the CANopen slave protocol. It provides four I/O slots for flexible expansion using ICP DAS’s I-87KW and I-8000 series analog or digital I/O modules, supporting a wide range of application needs.

• Status Monitoring of RS-485 Equipment such as Generator Sets

Generator sets and other equipment on the vessel communicate using the RS-485 interface (Modbus RTU protocol). To enable the LP-8421 Linux-based controller to monitor this equipment data in real time via an Ethernet interface (Modbus TCP protocol), the customer deployed the PDS-5105D-MTCP Programmable Serial-to-Ethernet Device Server.

The PDS Series Programmable Serial-to-Ethernet Device Servers feature a high-performance MiniOS7 operating system that boots in just one second. These devices include a Modbus TCP to Modbus RTU/ASCII gateway function, allowing RS-232/485/422 serial devices to connect to Ethernet networks. They are compatible with most SCADA and HMI systems that communicate using the Modbus TCP protocol.

In this case, the PDS-5105D-MTCP was selected. It offers one RS-232/485 port and up to nine RS-485 ports, making it ideal for applications that require connecting a large number of sensors, meters, or other serial devices. The unit also includes a 2-port Ethernet switch, which allows for simplified cascading of Ethernet devices, reducing cabling complexity, minimizing the need for additional switches, and lowering overall installation costs.

Additionally, the PDS-5105D-MTCP supports a LAN Bypass function. In the event of a power failure, this feature automatically activates to bypass the affected module, ensuring uninterrupted data transmission.

• Integration with the Vessel Safety System’s Host Computer

The LP-8421 controller transmits all monitoring data to the vessel safety system’s host computer via the Modbus TCP protocol, enabling centralized data monitoring and application-level analysis.

Benefits:

1. The ICP DAS solution enables real-time monitoring of vessel safety and damage control systems, significantly enhancing overall vessel safety.

2. ICP DAS offers highly compatible and reliable controllers, I/O modules, and gateways to help customers seamlessly integrate multiple vessel systems — including fire detection, compartment flooding monitoring, and generator set management — achieving centralized management with ease.

3. In addition to the vessel’s existing damage control system host, ICP DAS implemented local logic control through an additional control box. This local unit retrieves data via Modbus TCP and autonomously coordinates drainage systems, fire pumps, hull bottom valves, and ventilation mechanisms. By providing backup control in case the host computer fails to respond during emergencies, it further strengthens the reliability of the overall safety system.

ICP DAS One-Stop CAN Series Product Line

ICP DAS has decades of experience in the CAN Bus field and offers a comprehensive lineup of CAN/DeviceNet/CANopen/J1939 solutions. The product range includes PCI communication cards, Fieldbus converters, PACs, gateways, and remote I/O modules — designed to meet diverse CAN-based application needs such as data acquisition and processing, extending transmission distance, overcoming network topology constraints, interface conversion, and noise suppression.

In addition, ICP DAS provides a rich suite of software resources, including development tools, APIs, sample programs, OPC, ActiveX components, and third-party drivers, enabling users to quickly and efficiently develop robust monitoring systems.

• CAN Bus Converters

ICP DAS’s CAN Bus converters enable signal conversion between CAN Bus and various interfaces, including serial, USB, and Ethernet. By selecting the appropriate converter, users can easily manage and integrate devices that use different communication interfaces.

• CAN Series Programmable Automation Controllers (PACs)

ICP DAS has introduced three CAN series PACs: I-7188XBD-CAN, uPAC-7186EXD-CAN, and uPAC-5001D-CAN2. These controllers support a wide range of peripherals and communication ports, allowing integration with various interfaces such as CAN Bus, RS-232, RS-485, and Ethernet. To maximize openness and flexibility, all PACs run on the MiniOS7 operating system, enabling users to develop custom applications using C/C++ programming environments.

For more information about ICP DAS CAN Bus series products, please visit our official website: https://www.icpdas.com/en/product/guide+Industrial__Communication+Fieldbus__Communication+CAN__Bus

Conclusion:

ICP DAS solutions deliver exceptional stability and scalability, supported by a comprehensive product portfolio and one-stop service. With the expert planning of our professional team, this project successfully enhanced the integration and real-time monitoring reliability of the vessel safety systems, achieving a significant upgrade in overall equipment safety.

Additionally, ICP DAS offers customized solutions tailored to specific application requirements—serving the needs of various industries and working closely with clients to achieve outstanding results.

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October 21, 2025