standard features

PRYCO, INC.
EVOLUTION SYSTEM Detail
PRYCO, INC.
FUEL CONTROL and
MONITORING SYSTEM
PRODUCT
DESCRIPTION
P. O. Box 108, Mechanicsburg, IL 62545
Page 1
EVOLUTION Detail Specifications
PRYCO, INC.
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 initiate 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 networking.
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 ultrasonic 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 module 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 Manufacturing Execution System) or ERP (Enterprise Resource Planning)
P. O. Box 108, Mechanicsburg, IL 62545
Page 2
PRYCO, INC.
EVOLUTION SYSTEM Detail
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)
•
•
•
•
P. O. Box 108, Mechanicsburg, IL 62545
Page 3
EVOLUTION Detail Specifications
PRYCO, INC.
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 electronically protected against overloads and short circuits.
Power Supply Specifications (120 and 240 watts units):
Input Voltage
Universal Input 85-264
VAC;100-350 VDC
Input Current
120 watts—1.8 Amp
(Maximum@100VAC) 240 watts—3.5 Amp
Output Voltage
24 VDC
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)
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
P. O. Box 108, Mechanicsburg, IL 62545
Page 4
PRYCO, INC.
EVOLUTION SYSTEM Detail
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 actions 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 output downstream to your in-house system. The system can accommodate up to a total of seven communication ports. Acting as a slave to inhouse 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.
P. O. Box 108, Mechanicsburg, IL 62545
Page 5
EVOLUTION Detail Specifications
PRYCO, INC.
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. Illuminated 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 information 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 normally.
Two yellow linear-scaled graphics report fuel level in
“percent full” and in gallons. A digital readout of number 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.
P. O. Box 108, Mechanicsburg, IL 62545
Page 6
PRYCO, INC.
EVOLUTION SYSTEM Detail
PUMPS & MOTORS
This page contains input HOA switch and light graphics where an operator can control each pump motor of
the fuel system. A motor may operate in either automatic 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, control, and laboratory use, Part 1.
P. O. Box 108, Mechanicsburg, IL 62545
Page 7
EVOLUTION Detail Specifications
PRYCO, INC.
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 gravityfeed 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)
P. O. Box 108, Mechanicsburg, IL 62545
Page 8
PRYCO, INC.
EVOLUTION SYSTEM Detail
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 output.
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 common 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 activities of its operation.
P. O. Box 108, Mechanicsburg, IL 62545
Page 9
EVOLUTION Detail Specifications
PRYCO, INC.
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).
P. O. Box 108, Mechanicsburg, IL 62545
Page 10
PRYCO, INC.
EVOLUTION SYSTEM Detail
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 (099 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 voltage regulation (AVR) will step up low voltages to safe output levels without resorting to battery 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.
P. O. Box 108, Mechanicsburg, IL 62545
Page 11
EVOLUTION Detail Specifications
PRYCO, INC.
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.
3rd & Garvey Streets
P. O. Box 108
Mechanicsburg, IL 62545
Phone: 217 / 364-4467
Fax: 217 / 364-4494
Web Site: www.pryco.com
Email: Pryco@Pryco.com
Ver 1.00—03/09
P. O. Box 108, Mechanicsburg, IL 62545
Page 12