pryco, inc. evolution pryco, inc. · optional built-in rs232 or rs485 serial interface adapters, or...

PRYCO, INC. EVOLUTION SYSTEM Detail

P. O. Box 108, Mechanicsburg, IL 62545

FUEL CONTROL and MONITORING SYSTEM

PRYCO, INC.

PRODUCT DESCRIPTION

PRYCO, INC. EVOLUTION Detail Specifications


INTRODUCTION

The EVOLUTION is a Programmable Logic Controller (PLC) based system designed to control and monitor the activities of up to four pumps and motors of a Pryco fuel supply system. A color touch screen displays system functional status, alarm conditions, and historical logs. The Evolution PLC provides operational control of the overall fuel system. An ultra-sonic sensor accurately determines the level of the fuel in the tank. Electronic “action levels” settings control the activities of pumps and motors (supply and reverse flow), and initi-ate signals for a full compliment of alarm conditions activating a common external alarm, light, or similar device. Using licensed software, WindSRV , it possible to link your OPC (object linking of devices for process control) or DDE (older version of OPC) compliant Windows - based software to any IDEC programmable logic controller. Modbus protocol is standard. This link may use an optional built-in RS232 or RS485 serial interface adapters, or longer range Ethernet network-ing. That means any industrial HMI*, SCADA, general data acquisition, MES, or ERP will connect through WindSRV to Evolution system. All you have to do is install the server software on your PC running Windows, and you have a low-cost data acquisition and monitoring system using your own computer and the Evolution PLC. The basic PLC portion of the Evolution system is made up of a power supply module, an ultra-sonic sensor mentioned above, and a logic controller that controls and processes incoming data and initiates pump motor activities and alarms as necessary. A graphical, color LCD Touch-Screen provides an Operator Interface Terminal. Depending upon the requirements of the fuel system design, an optional communications mod-ule and/or an optional (additional) I/O module may be added. The Evolution system is totally electronic except for a redundant fail-safe critical high level sensor.

The Evolution System

* HMI (Human Machine Interface), SCADA (Supervisory Control and Data Acquisition), MES Manufac-turing Execution System) or ERP (Enterprise Resource Planning)



STANDARD FEATURES

The Evolution system comes with an impressive list of standard features:

• 120/240 VAC-to-24 VDC power supply—“safety extra-low voltage” (SELV) (Page 4)

• Ultra-Sonic Sensor (Page 5)

• Color LCD Touch Screen for an Operator Interface Terminal (Page 6)

• Fuel Level Gauge Scaled in Percent Full and Gallons (Pages 6 & 8)

• Power Available Annunciator Light (Page 8)

• HOA Switching (Page 8)

• Audible Alarm Silence Switch (Page 8)

• Critical High Notification Feature (Page 8)

• High Fuel Level Notification Feature (Page 9)

• Low Fuel Level Notification Feature (Page 9)

• Critical Low Level Notification Feature (Page 9)

• Secondary Containment Detection Alarm Notification (Page 9)

• Discrete Normally Open (N.O.) Contacts for All Alarms (Pages 8 & 9)

• Historical Log (Page 9)

• Modbus Protocol (Page 2)

OPTIONAL FEATURES (described starting on Page 10)

• Duplex Fill Pump and Motor (Addition To Standard Pump/Motor) (Page 10)

• Reverse Flow Pump Controls—Single or Duplex (Pumps & Motors Extra) (Page 10)

• Pump(s) Fail Detection w/Automatic Reset (Page 11)

• RS232/442 & Ethernet (10BASE-T/100BASE-TX) Comm. Ports (Pages 5)

• UPS Battery Backup and Surge Protection (Page 11)

• WindSRV PC Driver Software (Page 11)



24 VDC POWER SUPPLY

This compact power supply has Universal input voltage for Worldwide industrial integration with primary switched-mode regulator technology. It features low output ripple 24 VDC and a 240 Watt / 10 Amp (shown below) or a 120 Watt / 5 Amp output rating. The output is electroni-cally protected against overloads and short circuits. Power Supply Specifications (120 and 240 watts units):

Special Certifications – Class1-Div2 Rated (UL1604), Semi F47 Approved, UL508 Applicable Directives - EMC: EN61204-3 (EMI: Class B, EMS: Industrial), EN50178, EN61000-3-2 A14 class A, LVD: EN60950

Input Voltage Universal Input 85-264 VAC;100-350 VDC

Output Voltage 24 VDC

Input Current (Maximum@100VAC)

120 watts—1.8 Amp 240 watts—3.5 Amp

Output Current 120 watts—5 Amp 240 watts—10 Amp

Internal Fuse Rating

120 watts—4 Amp 240 watts—6.3 Amp

Voltage Adjustment

±10% (V. Adj Control on Front)

Over Voltage Protection

120% minimum Shutdown

Over Current Protection

103% to 110%, Auto Reset

“Power-On” Indicator

LED (Green) “Voltage Low” Indicator

LED (Amber)

Operating Temperature

-10º C to 60º C (14º to 140º F)

Operating Humidity

20% to 90% - Relative (No Condensation)



ULTRA-SONIC SENSOR 4-20ma

This device emits a signal at a narrow beam angle downwards into a tube extending the depth of the tank. When the signal encounters an object (the fuel), it bounces back to the emitting device that has a built-in receiver. The elapsed time between emission of the signal and its return is converted into an electrical voltage, which then is changed to inches of air space from tip of emitter to fuel level.

Important to note - nothing (inductance probe, or such) touches the fuel. Hence, there are no erratic and low voltage level readings caused by gum-up or other undesirable phenomenon which are inherent to similar out-dated systems. Periodic cleaning and re-adjustment of probes and the system is not necessary.

LOGIC CONTROLLER—CPU

This rugged, compact module is “brains” of the Evolution system. Logic procedures direct various action to be initiated based upon input from the Ultra-Sonic level sensor or external sensing switches. This module formats and directs the display of the variable content of the LCD screen pages and to the Communications Module (below) as ac-tions and conditions occur. A standard RS232C port is built into every CPU controller module. This port is rated for a maximum of 50 ft. and is dependant on cabling, electrical noise, etc. We recommend using a RS485 communication module described below. If you need additional ports, a different protocol, or distance, you may add a Communications expansion Modules (shown below).

COMMUNICATIONS MODULES

This optional strong communications module directs Logic Controller out-put downstream to your in-house system. The system can accommo-date up to a total of seven communication ports. Acting as a slave to in-house building management systems, Modbus protocol is standard. This optional module provides RS485/RS232 for data link or modem communication extending distance rating beyond the 50 foot range to 656 feet.



OPERATOR INTERFACE TERMINAL

An LCD touchscreen provides a series of graphical data presentations in vivid color to monitor and control the Evolution system. Illuminated “soft” pushbuttons replace physical mechanical switches to allow an operator to input data to control the operation of the fuel system. Illumi-nated graphic lamps communicate on/off normal states and report alarm conditions.

MAIN MENU

This is the “home” touch screen page of the Evolution system. From here, using soft buttons an operator may select subsequent pages to monitor and control the fuel system PLC.

SYSTEM MENU

This password protected page contains critical infor-mation relevant to the overall Evolution PLC system. The system password is maintained here.

CONTROL PANEL

This is the monitoring screen page. Each monitored feature that is available to the system is represented here as a solid illuminated lamp. If a feature becomes “active” the lamp graphic flashes. An operator can determine at a glance if the system is operating nor-mally.

Two yellow linear-scaled graphics report fuel level in “percent full” and in gallons. A digital readout of num-ber of gallons (blue) is shown above these areas.

Two soft push-button switches are also located on the page—an “ALARM SILENCE” switch, which is a standard feature; and a “PUMP FAIL RESET” switch if an optional fuel flow switch (option # 372) is installed.



PUMPS & MOTORS

This page contains input HOA switch and light graph-ics where an operator can control each pump motor of the fuel system. A motor may operate in either auto-matic or manual mode. The illuminated LCD boxes to the right of each switch report the switch position of its associated motor. Each pump and motor has it own HOA switch along with run-time hour display. Motor assignments are:

• Standard Duplex Mode—(Supply or Reverse) Pump and Motor 1 is always “lead pump”; (Supply or Reverse) Pump and Motor 2 is always “lag Pump”

• Automatic Mode—Will alternate “lead pump” upon each initial start cycle. • Manual Mode—User defined “lead pump” using lead/lag soft push-button

switch.

HISTORY

This screen page reports a time/date historical log of pump motor activities and alarm conditions. The soft push-buttons at bottom assist in scrolling through the log.

PARAMETERS This password-protected page contains level settings at which specified actions (pump motor on/off, high low fuel levels, etc.) are to begin. Optional Pump fail timers are also displayed for user defined time. This allows dynamic fine tuning at the job sight.

CERTIFICATION

CE Marked, TÜV, c-UL, UL 508, UL 1310 (PS5R-SB, -SC, -SD), UL 1604, EN 50178:1997, LVD: EN60950:2000, EMC: Directive, EN61204-3:2000 (EMI: Class B, EMS: Industrial) Safety requirements for electrical equipment for measurement, con-trol, and laboratory use, Part 1.



STANDARD FEATURES

ELECTRONIC FUEL LEVEL GAUGE

Two graphical gauges that represent fuel level in the tank. They display both percent full and gallons remaining. The 100% or FULL level is normally set to the Fill Pump shut off level (not the physical top of the tank); the EMPTY level of the gauge is normally set to the bottom of the tank.

POWER AVAILABLE “LIGHT”

This green LED lamp at the bottom of the LCD touch-screen is used to report that power is on and the Evolution system is energized.

HOA SWITCH

An HOA soft push-button switch is displayed for each pump motor on the PUMP & MOTOR screen page.

• In the ON position, the EVOLUTION system surrenders automatic control of the pump and motor except at action levels at the specified control points --Reverse pump(s) on, Critical High and High Fuel.

• In the AUTO position, the EVOLUTION system automatically controls the activities of the motors based upon fuel level readings and control points.

• In the OFF position, the pump motor is offline to all actions.

.

ALARM SLIENCE SWITCH

This soft push-button switch is used to silence a common alarm horn (if installed) that will sound if an abnormal condition exists. (The horn will shut off automatically when the condition is corrected.)

CRITICAL HIGH FUEL NOTIFICATION FEATURE

This feature will illuminate the Critical High Alarm lamp graphic on CONTROL PANEL screen page when fuel level reaches a predetermined set point, plus shut-down any supply pump(s). Sends a signal to a common alarm output. A Critical High Alarm Dry Contact is provided, (1 - N.O). If the day tank is supplied by a gravity-feed main tank, this is a good place to receive a signal to close a normally open solenoid valve in the inlet line. A Common Alarm Dry Contact is Provided, (1 - N.O)



HIGH FUEL NOTIFICATION FEATURE

This feature will illuminate the High Alarm lamp graphic on CONTROL PANEL screen page when fuel level reaches a predetermined set point, plus shut-down any supply pump(s). Sends a signal to a common alarm output. A High Alarm Dry Contact is provided, (1 - N.O). A Common Alarm Dry Contact is Provided, (1 - N.O)

LOW FUEL NOTIFICATION FEATURE

This feature will illuminate the Low Alarm lamp graphic on CONTROL PANEL screen page when fuel level reaches a predetermined set point. Sends a signal to a common alarm out-put. A Low Alarm Dry Contact is provided, (1 - N.O). A Common Alarm Dry Contact is Provided, (1 - N.O)

CRITICAL LOW FUEL NOTIFICATION FEATURE

This feature will illuminate the Critical Low Alarm lamp graphic on CONTROL PANEL screen page when fuel level reaches a predetermined set point. Sends a signal to a com-mon alarm output. A Critical Low Alarm Dry Contact is provided, (1 - N.O). A Common Alarm Dry Contact is Provided, (1 - N.O)

TANK RUPTURE ALARM NOTIFICATION

This feature will illuminate the Tank Rupture lamp graphic on CONTROL PANEL screen page when a Tank Rupture occurs, plus shut-down any supply pump(s). Sends a signal to a common alarm output. A Tank Rupture Alarm Dry Contact is provided, (1 - N.O). A Common Alarm Dry Contact is Provided, (1 - N.O) HISTORICAL LOG The EVOLUTION system maintains a time/date stamped log of events pertaining to activi-ties of its operation.



EVOLUTION SYSTEM OPTIONAL FEATURES

DUPLEX SUPPLY PUMP

An additional fill pump and motor of any size and voltage may be installed on the day tank, subbase or on a remote pumping unit and controlled by EVOLUTION SYSTEM. This second pump/motor is referred to as (Supply Pump #2) on the EVOLUTION SYSTEM control panel and by software. Pumps and motors may be tank mounted or upon an option remote pump unit/pump set; the EVOLUTION system will control it regardless where it may be mounted. Supply Pump #2 has its own “HOA” soft push-button switch as well as a “turn ON” level and “turn OFF” level, and pump running illuminated lamp.

REVERSE FLOW PUMP(s) - SINGLE or DUPLEX

As a safety feature, the fuel supply system can be optionally configured with a sub-system that will pump the fuel in the day tank or subbase to another container – normally back to the main supply tank. This operation is referred to as “reverse flow”. It can be configured as either a single pump/motor or as a duplex. The single pump/motor of a reverse flow (or the first of a duplex setup) is always referred to as Reverse Pump #3. If the configuration is a duplex reverse flow, the second is Reverse Pump #4. Both reverse pumps have their own set of “HOA” soft push-buttons, “turn ON” levels, “turn OFF” levels, and pump running illuminated lamp. When a reverse flow pump is turned ON, any supply fill pump(s) will automatically be turned OFF in case either has caused the problem. The voltage, size, type of current, etc. of reverse flow pump(s) and motor(s) are not required to match those of the fill pump(s) and motor(s).



PUMP FAILURE w/MANUAL RESET

This option works in conjunction with an optional Flow Switch to report a “Pump Fail Alarm” condition in the fuel line from the main storage tank. Without this option, there is a possibility of the pump running dry (which will eventually cause pump damage). When a pump/motor starts, if fuel is not detected after the users predetermined set time (0-99 seconds. The respective pump/motor will be shut-down. If system has the duplex pump/motor option, second pump/motor will start after first pump/motor times out. If second pump/motor does not detect fuel, it will be shut-down after the user predetermined set time. This is standard operation for Supply pump(s) or Reverse pump(s) with duplex pumps. All pump fail alarms have a common manual reset switch that must be pushed to reset and clear the alarm and reset the pump/motor. The following actions will occur after system encounters a pump failure:

• Shuts off pump/motor • Start second pump/motor (if installed) • Lights the appropriate annunciator on the control panel • A Pump Fail Alarm Dry Contact is provided, (1 - N.O.) • A Common Alarm Dry Contact is provide, (1- N.O.)

UPS BATTERY BACKUP and SURGE PROTECTION Line Conditioning battery backup UPS systems that guard against surges, spikes, sags, brownouts and other power abnormalities. Several models are available to choose from depending upon desired watt-output rating and UPS battery run times. The automatic volt-age regulation (AVR) will step up low voltages to safe output levels without resorting to bat-tery power. WindSRV PC DRIVER SOFTWARE

Windows based driver software to link the Evolution PLC to a customer’s PC computer using RS232, RS485, and Ethernet. Required for any industrial HMI, SCADA, general data acquisition, MES, or ERP.



Over two acres under one roof is the home of Pryco — industry pioneers of safety, standards, and codes for fuel systems for emergency and standby power generation systems.

PRYCO, INC.PRYCO, INC.PRYCO, INC.PRYCO, INC.

3rd & Garvey Streets P. O. Box 108

Mechanicsburg, IL 62545

Phone: 217 / 364-4467 Fax: 217 / 364-4494

Web Site: www.pryco.com Email: [email protected]

Ver 1.00—03/09

pryco, inc. evolution pryco, inc. · optional built-in rs232 or rs485 serial interface adapters, or...

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