When Extreme Funfairs in Ireland commissioned us to upgrade their Fabbri “Wild Mouse” coaster, the brief was clear: simplify operations, raise safety integrity, and make maintenance faster and smarter. We delivered a fully centralised control solution that brings safety, diagnostics, and everyday operation into one compact, operator-friendly console.

What we built

Centralised console

A single enclosure houses the PLC, safety modules, and all air circuits. Consolidating control hardware reduces wiring complexity, shortens installation time, and improves serviceability.

A 10-inch industrial touchscreen provides operators with at-a-glance status, ride modes, and clear alarms, while maintenance staff can dive into detailed diagnostics, I/O status, and pneumatic schematics.

Safety and standard control on one platform

The system runs on a Siemens S7‑1500 PLC platform, enabling both standard and safety functions on a common backplane. This architecture streamlines engineering, reduces interface points, and ensures consistent behaviour across the system.
 

Smarter field architecture

All sensors are integrated over two AS‑i Safe networks (ASISafe), cutting field wiring down to just four two‑wire connections. Fewer terminations mean fewer potential faults, quicker commissioning, and cleaner routing throughout the ride structure.
 

Pneumatics integrated

Air circuits are built into the same console with clearly labelled manifolds and monitored valves. Pressure, valve actuation, and cycle counts are captured for condition‑based insights.
 

How it helps day to day
 

Faster start-up and checks

• • Guided pre‑flight checks on the HMI walk operators through safety confirmations and interlocks, reducing training time and helping ensure consistent procedures.

Clear diagnostics, minimal downtime

• • Plain‑language fault messages pinpoint the exact device and location on the ride, with suggested corrective actions. Maintenance can isolate, test, and reset directly from the touchscreen where appropriate.

Reduced wiring, increased reliability

• • The AS‑i Safe backbone slashes copper, junction boxes, and terminations. That directly translates into higher reliability and simpler troubleshooting in harsh outdoor environments.

Future-ready

• • The S7‑1500 platform leaves headroom for added features such as remote support, performance dashboards, or integration with park‑wide systems.

Safety, documented
 

The complete solution is engineered and verified for compliance with EN 13814 functional safety requirements for amusement rides and devices. Safety functions—such as emergency stop, restraint and station gate interlocks, block section supervision, and overspeed/position monitoring—are implemented using safety-rated modules on the S7‑1500 platform with validated safety I/O on AS‑i Safe. All safety functions are supported by a full lifecycle file: hazard analysis, SIL/PL assessments, proof test procedures, and traceable verification records.

Operator experience

• Intuitive screens: mode selection (maintenance, test, operation), train/block overview, live I/O, pneumatic status, and trends.
• Contextual help: each alarm includes a description, likely causes, and recommended steps.
• Maintenance tools: valve jog, input simulation (where safe), and timestamped event logs to speed root‑cause analysis.

Project snapshot

• Client: Extreme Funfairs (Ireland)
• Ride: Fabbri Wild Mouse
• Core PLC: Siemens S7‑1500
• Safety networks: 2 x AS‑i Safe
• HMI: 10" industrial touchscreen
• Architecture: Centralised console with integrated pneumatics
• Standards: EN 13814 functional safety compliant

Why centralise?
 

Wild Mouse coasters pack complex block logic, restraints, and station devices into a compact footprint. Traditional distributed panels can multiply terminations and complicate access. By centralising the control and pneumatics:

• Service points are in one place, under shelter, with clear labelling.
• Environmental protection is simpler and more robust.
• Expansion—additional sensors, auxiliary devices, or analytics—becomes a modular add-on, not a redesign.

Results

• Cleaner install with dramatically reduced field wiring
• Faster fault-finding and shorter resets during operations
• A unified safety and standard control environment with traceable compliance
• A clearer operator interface that supports safe, efficient throughput

If you’re running legacy control on a classic coaster and want safer, simpler, and more serviceable operations, this architecture shows what a targeted modernisation can deliver—without changing the ride’s character.