Pyrokos Control System

OPERATION & MAINTENANCE MANUAL

alliedpumps.com.au
 CONTENTS
PYROKOS PUMP CONTROL SYSTEM 3 - 28
1. Functional Overview 3-5
2. Hardware Overview 6-7
3. Software Specification 8
a. Display Module 8
b. System Start up Display 8
c. Numeric Display 9
d. Numeric Displays out of Range Conditions 10
e. LED Indicators 11
f. Calibration Factors 12
g. VFC Relay Outputs 13
h. Remote Display Functions 13
i. Panel Switches 14
j. Main Module LEDs 14
k. Main Module Button 14
l. Parameter Register Descriptions 15 – 19
m. Programming Mode 20 – 23
n. View Log Mode 24 – 25
o. Data Logging 26
p. Diagnostic Port 27
4. Typical Drawing 28

APPENDIX A: Warranty and Service Information

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FUNCTIONAL OVERVIEW
The unit has 2 main modes of operation:
1. FIRE PUMP CONTROL
2. STOP-START PUMP CONTROL

NOTE: - This version also requires processor on the main relay module (D13242) to have Software
Version 0_9 (Normal Fire Pump Mode) or Version 0_9ONOFF (Stop-Start Mode)

The MODE is read from the Engine Parameter Register 0 (Model ==D13242 for FIRE CONTROL Mode and
Model==D13243 for STOP –START Mode).

The software version label shows:

FIRE PUMP Control – S/w version Label is V0_9

STOP-START Mode – S/w Version label is V0_9 ONOFF

The system MODE can be identified on the second startup display showing either:-

“FFFF” for FIRE CONTROL MODE

“bbbb” for STOP-START MODE

a. FIRE PUMP CONTROL

The Fire Pump Controller has the primary function of starting a diesel fire pump with a high degree of
reliability.

The Specification document “Fire Pump Controller Specification_2.doc” provides further background into
the hardware and software features.

The main processor and peripheral hardware (e.g. Display, switches and relays) have ancillary functions to
provide the following:
(a) Monitoring with numeric indications of levels
(b) Status indications of power and alarm conditions
(c) Button inputs for user control of
(1) Viewing and Setting Calibrations & Parameters
(2) Testing
(3) Resetting Alarms
(4) Manual Override

b. STOP-START CONTROL

The STOP-START control allows the pump to be STARTED with a closed contact on the Pressure Switch
input and then to STOP the pump by opened contact on the Pressure Switch input

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The functioning of the Display, Monitoring, Alarms, Logging and User Parameters are mostly the same as for
the FIRE PUMP CONTROL mode, with the main differences being:-

(1) The Pressure Switch does not generate a common alarm, but the ON/OFF status is still shown
on the LED display.
(2) The “STOP” relay can be optionally configured as a “RUN” relay and switches the fuel solenoid
continuously on when engine is cranking and running, and switches it off when engine is required
to be stopped.
(3) Any other of the Common Alarms will force the Engine Processor into STOP-OVERRIDE state
which will shut the pump off until the fault can be cleared.
(4) User Configured Delays for Engine Start, Stop and Restart times.
(5) User Configured Delays for the alarm inputs to prevent false triggering.
(6) Fuel Low Level Warning, as well as Low Fuel Shutdown. Fuel Low Level Warning can also be
assigned to one of the VFC relays.
(7) Provision is for one only Battery and Charger. The battery voltage is shown in the “Start”
battery display and the battery charging current is now shown in the “Control” battery display.

The Engine Processor can also be user configured for 2 modes for RUN or STOP fuel solenoid operation.
This program via the display menu 43 or Serial diagnostics, update register command “2 63”

MODE=0 (Default): RUN solenoid operating mode – which is ON during cranking and is OFF
when the engine is OFF

MODE=1: STOP solenoid operating mode – which is OFF for engine cranking and run and is
switched ON momentarily to shut down the engine, then returns to OFF when the
engine has stopped.

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HARDWARE OVERVIEW
a. COMPONENTS
Referring to the block diagram in Appendix 3.1, the following main components are identified, with a brief
description of functions.

2.a.1 D13242 – Main Module

This module provides the central hub for all interconnections.
It has an on-board microcontroller as a standalone processor which is controlling the engine starting
operations.
It contains relays to operate the engine crank and stop solenoids.
It connects to the D13241 Display Module
It connects to the D13244 VFR Relay Modules
It has 6 push button tact switches for parameter viewing and configuration.
It has interfaces for Engine sensors.

ENGINE START PROCESSOR.

This is a stand-alone processor, which can function independently of the main processor module.
It has only the essential inputs and driver outputs for the engine start functions.

This processor has sensor inputs for:-

Low Pressure (Fire Detection System),
RPM / Tacho Sensor (Engine Speed)

This processor also detects the 6 on-board tact switches.

2.a.2 D13241 – Display Module

This module is mounted on the front panel and is the primary operator interface
This module provides 9x numeric displays and 18 LED indicators.
It has inputs for 5 panel switches.
The module communicates using RS485 line interface.
It uses the Modbus Protocol for relaying control and status information.

2.a.3 D13241 – Remote Display Module

A second remote display can be connected to J1 – REMOTE DISPLAY connector on the main
module D13242.
It uses Modbus protocol over an RS485 line interface.
The Cable distance is typically up to 2Kms.
Two configurable option bits are used to Enable the Remote Display, and also to Enable remote
buttons.

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2.A.4 D13244 – Relay Output Module
Each D13244 module has 8 relays. Two of these have SPDT Form C change over contacts, and 6
have SP Form A contacts (Normally Open)

Two of these modules can be connected to provide a total of 16 relay outputs.

2.A.5 D13401 – Main Processor Module

This module provides monitoring, display and status logging functions.
Note – it does not have any control of the engine starting, which is performed by the dedicated
processor on the D13242 Main Module.

Logging is saved to 32KByte non-volatile EEPROM.

A FLASH Ram IC can also be fitted

2.a.6 Batteries

1 or 2 batteries are provided depending whether the system is for FIRE pump control or is for
STOP-START system .
These may be 12 or 24Vdc, and must be the same voltage

NOTE: THE MAIN MODULE (D13242) MUST BE MATCHED FOR CORRECT VOLTAGE

FIRE PUMP CONTROL MODE:

2 Batteries are provided for additional reliability of the Fire Pump System.
(1) Crank Battery -is main 12 or 24 Vdc battery used to drive the starter motor
(2) Control Battery – provides 12 or 24Vdc battery to supply the control circuits.

The Engine can also be manually started from the Control Battery if required.

STOP-START PUMP CONTROL MODE

1 Battery only is provided for the starter motor cranking and also powers the Control Circuits.

A 3.0V Lithium Battery is also provided on the main processor module (D13401) which maintains
operation of the Real Time Clock

2.a.7 D13243 – Crank Battery Charger

This is a charger dedicated in maintaining the optimum charge capacity of the Crank Battery.
Charging current is monitored by the Main processor module.

2.a.8 D13401 – Control Battery Charger

NOTE: USED FOR FIRE PUMP CONTROL SYSTEMS ONLY
This is a charger dedicated in maintaining the optimum charge capacity of the Control Battery.
Charging current is monitored by the Main processor module.

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 2.a.9 Engine Solenoids
Three solenoids are operated,
(1) Cranking Solenoid
(2) Alternator Isolate Solenoid
(3) Engine Stop Solenoid

2.a.10 Engine Sensing

The following conditions are monitored by the Main Processor.
(1) Fuel Gauge
(2) Low Fuel Switch
(3) Oil Sender (Pressure)
(4) Temperature Sender
(5) Engine Speed / RPM

2.a.11 Other Sensing

The following conditions are also monitored by the Main Processor
(1) Crank Battery Voltage
(2) Crank Battery Current
(3) Control Battery Voltage (FIRE Systems only)
(4) Control Battery Current (FIRE Systems only)
(5) Mains Voltage Available to Crank Charger
(6) Mains Voltage Available to Control Charger (FIRE Systems only)
(7) Manual Control Switch
(8) Manual Start Switch
(9) Local 12V Voltage

2.a.12 Diagnostic Port

Provides RS232 Serial Interface
A simple command console allows connection to a PC running a simple ASCII terminal (E.g. MS
Windows Hyperterm)

The user can view and set parameters, and dump the status log.

2.a.13 USB Port

The module implements a CDC class which means it will appear as a com port on the PC.
Although the PC may allow com port parameters such as baud rate to be set they have no effect.

The USB port runs the same command console as for the Diagnostics Port.

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SOFTWARE SPECIFICATION

a. DISPLAY MODULE

The document “D13241_user_manual_A0_1.doc” describes the operation of the Display Module.

Note the following:-

The module uses the Modbus Protocol.
In preparing this product the following documents from Modbus-IDA.org were considered:-

MODBUS Application Protocol Specification V1.1a

MODBUS over serial line specification and implementation guide V1.01

The implementation is a reduced set of that proposed in these documents and adjusted to
suit industry conventions
Default Address is 4
Default Data Format is 9600 Baud, 8 Bits, Even Parity, 1 Stop bit

The main processor module will need to implement the api as a Modbus HOST.

It will need to be poll the display frequently (ideally 10x per second or at least 5x per second) so that
the button functions are responsive.

LEDs and Numeric Instrumentation Displays should be updated as the values are changed and within
1 second response.

b. SYSTEM STARTUP DISPLAY

When the system is started a sequence of numbers appears in the numeric LED fields

FIRST SCREEN:
RPM – Display Software Version
OIL PRESSURE – Display Mode

SECOND SCREEN:
RPM – Main Processor Software Version
HOURS – Engine Processor Software Version
START BATTERY – SYSTEM VOLTAGE (12/24V)
CONTROL BATTERY – SYSTEM MODE
“FFFF” = FIRE PUMP CONTROL

“bbbb” = STOP-START PUMP CONTROL

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c. NUMERIC DISPLAYS
There are 9 numeric 4 digit displays on the display module.

The numeric displays are assigned as follows:-

Display Display Function Units Range Resolution

Number Number
FIRE STOP-
SYSTEM START
MODE MODE
D1 D1 Hours Hours 0..9999 1
D2 D2 Oil Pressure kPa 0..600 1
D3 D3 Temperature DegC 0..200 1
D4 D4 Alternator Amps Amps 0..100 0.1
D5A ** D5 Start Battery Volts Volts 0..35 0.1

D5B ** D6 Start Battery Charging Amps 0..10 0.1

Amps
D6A ** Control Battery Volts Volts 0.35 0.1
(FIRE SYSTEMS ONLY)
D6B ** Control Battery Amps 0..9 0.01
Charging Amps
(FIRE SYSTEMS ONLY)
D7 D7
D8 D8 Fuel Tank Level % 0..100 1
D9 D9 Engine Speed RPM 0..9999 10

NOTE: Displays marked ** have different function depending whether the system is running in FIRE
PUMP CONTROL or STOP-START CONTROL mode

In FIRE mode the displays are multiplexed with voltage and amps.

These alternate at a 3 second rate.

The displays show “nn.nu” for Voltage and “n.nnA” for Amps

In STOP-START mode the display D5 shows the Battery Voltage, and D6 shows the battery charge
current.

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d. NUMERIC DISPLAYS – OUT OF RANGE CONDITIONS

The displays flash at a slow rate when out-of-range condition is detected.

Display Display Function Units Out of Range Conditions

Number Number
FIRE STOP-
MODE START
MODE
D1 D1 Hours 0.1 Hours >9999 or if invalid read from EEPROM
<1000
then 1 Hr
>=1000
D2 D2 Oil Pressure kPa Low Pressure
Set by Parameter
D3 D3 Temperature DegC High Temp
Set by Parameter
D4 D4 Alternator Amps Amps >99.9

D5A ** D5 Start Battery Volts Volts <10 or >16 (12V System)

<20 or >32 (24V System)
D5B ** D6 Start Battery Charging Amps <0 or >9.9
Amps
D6A ** Control Battery Volts Volts <10 or >16 (12V System)
(FIRE SYSTEMS ONLY) <20 or >32 (24V System)
D6B ** Control Battery Amps <0 or >9.9
Charging Amps (FIRE
SYSTEMS ONLY)
D7 D7 Not Used
D8 D8 Fuel Tank Level % Low Fuel
Set by Parameter
D9 D9 Engine Speed RPM Low and High Engine Speed
Set By Parameters

e. LED INDICATORS

The LED indicators are allocated as per the following table.

The LED will be lighted when the Condition is exceeded

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 D13241 LED Allocated Function Alarm/Led On Conditions
Register & Bit Position to
Map Position Common
Alarm
22_0 D10 Pump Available Engine start processor is in
STOPPED/Ready State & no other
common alarms are indicated
22_1 D11 Y Pump Running Engine start processor is in RUN state
or RPM > 100RPM
22_2 D12 Y Auto Start When Auto Isolate Switch is operated
Isolated via the Display module and Engine start
processor is in AUTO_ISOLATED
mode
22_3 D13 Y Engine Fail to Engine start processor is in
Start RESTART_LIMIT state. Is reset with
Alarm Reset Button
22_4 D14 Y Low Fuel Level Fuel Level < parameter set point or fuel
level sensor is operated.
Cleared by Alarm Reset button if the
fault is rectified
22_5 D15 Y Engine Engine start processor is in
Overspeed STOPPED_OVERSPEED state.
Shutdown Cleared by Alarm Reset button
22_6 D16 Y High Engine Temperature >120 DegC
Temperature
22-7 D28 Y Low Oil Engine Running & <Parameter Set Low
Pressure
22_8 D17 Y Control Battery Control Batt Voltage <13V & Charge
Charger Fail current < 1Amp
(FIRE SYSTEMS
ONLY)
22_9 D18 Y Start Battery (<8V when Engine start processor is in
Low Voltage CRANKING state or Manual Cranking)
or otherwise <11.8V Cleared by Alarm
Reset button
22_10 D19 Y Control Battery <8V when Manual Cranking from
Low Control Battery or otherwise <11.8V
Voltage(FIRE Cleared by Alarm Reset button
SYSTEMS
ONLY)
22_11 D20 Audible Alarm When Audible alarm is in a muted state
Muted either via the MUTE switch via the
Display module or the EXTERNAL
MUTE input. Cleared by Alarm Reset
Button

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 22_12 D21 Y System Low On when the Low Pressure signal is
Water Pressure received via the engine start processor
for more than 5minuntes.
Cleared by Alarm Reset button
22_13 D22 Y Water Supply ??
Tank Low Level
22_14 D23 AUX 1 When Aux 1 (P_DIN3) is pulled low

25_0 D29 Power Available ON when Internal 12Vdc is within the

range 8V to 20V
25-1 D30 Y AUX 2 When Aux 2 (P_DIN5) is pulled low
25_2 D31 Y Start Battery Start Batt Voltage <13V & Charge
Charger Fail current < 1Amp

f. CALIBRATION FACTORS

2.f.1 Temperature Calibration

Temperature Calibration simply selects a Calibration Table to suit the particular Temperature Sensor

Currently there are two Calibration Tables available

(0) Table 0 = Temperature Sensor type VDO 320.002
(1) Table 1 = Temperature Sensor VDO 320.021

2.f.2 Oil Pressure Calibration

Oil Pressure Calibration simply selects a Calibration Table to suit the particular Oil Pressure Sensor

Currently there is one Calibration Tables available

(0) Table 0 = Oil Pressure Sensor type VDO 360.002

2.f.3 Fuel Sensor Calibration

Fuel Sensor Calibration simply selects a Calibration Table to suit the particular Fuel Sensor

Currently there are 2 Calibration Tables available

(0) Table 0 = Linear 180 Ohms Sensor

(1) Table 1 = Linear 90 Ohms Sensor

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g. VFC Relay Outputs

There are 8 Voltage Free Contacts (VFC) available,

A second Relay Module can be added to provide and additional set of 8 relays for a total of 16 relay outputs.

These are configured via Registers 27 to 42. Refer Table 2.l.32.l.3

** NOTE: COMMON ALARM is activated when any of the following alarms are on:-

MAINS POWER FAILURE (AFTER TIMEOUT IN REGISTER 26)

PUMP RUNNING (FIRE PUMP MODE ONLY)
ENGINE FAIL TO START
LOW FUEL
OVER-SPEED
ENGINE HIGH TEMPERATURE
LOW OIL PRESSURE
START BATTERY CHARGER FAILED
CONTROL BATTERY CHARGER FAILED (FIRE PUMP MODE ONLY)
START BATTERY LOW VOLTAGE
CONTROL BATTERY LOW VOLTAGE FIRE PUMP MODE ONLY)
LOW PRESSURE

TANK LOW LEVEL

AUX 2 INPUT
INTERNAL FAULT

h. Remote Display Functions

NOTE – Remote display requires main processor software version A1.4 or later and also
requires the Engine Control processor on the main relay module (D13242) to have Software
Version 0_9 (Normal Fire Pump Mode) or Version 0_9ONOFF (Stop-Start Mode)

The second remote display is connected to J1 – REMOTE DISPLAY connector on the main module
D13242.
Both the older D13241 display module and new D132431 display modules are able to work as either
main display and/or remote display without change to hardware or firmware.
Both Displays mirror each other in the information which is displayed and also button functions, e.g.
The buzzer will sound at both displays, and the mute button will stop the buzzer at both display
units,
Panel switches for Mute, Lamp Test and Alarm Reset are operational, whilst the Auto Isolate, Speed
Test, Start and Stop buttons are not available to be used.

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 In programming mode, only the local display will show the parameter details, while the remote
display will display ‘Prog’, and the display will give a short beep and start flashing.

Connection to the remote display will be via the dedicated 4 wire screw terminals J15 on the
D13242 main PCB. Note - 12Vdc supply @1.0 Amps may be required for the remote display if the
cable voltage drop is more than 2V.

i. Panel Switches

REFER to The Specification Doc Section 5.1 for the functional descriptions

j. Main Module LEDs

The LEDs indicate the system status.

Generally speaking, if the PUMP is ready for start the “PUMP AVAILABLE” LED will be on.

Otherwise, if it is not on then a fault indication will be given by one or more of the other LEDs.

Excepting for “System Low Water Pressure” LED which for STOP-START mode does not cause a
fault condition, but still reflects the current status of the LOW Pressure input.

k. Main Module Buttons

Six Buttons are provided – Esc, Enter, Left, Right, Up and Down.

These are used to place the system into a programming and diagnostics mode.

See Section below for operation of these.

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Parameter Register descriptions

2.1.1 MAIN PROCESSOR Register descriptions

The following parameter registers parameters (16 bits wide) are used for controlling the functions of the
system. They are available for reading (R) setting or writing (W).
They may be viewed and set via the buttons on the main module or via the RS232 Diagnostics port

Holding
Type Access Name Units Comment
Register Default
0 Unsigned R MODEL 1324 For D1324
10 x
version.
1 Unsigned R SW_VERSION_MAIN So version
0 2.7 would
be 27
2 Unsigned R SW_VERSION_ENGINE_START 0
See Table
3 Unsigned R/W BITMAPPED OPTIONS 2.l.2
0
4 Unsigned R/W Spare 0
5 Unsigned R/W Spare 0
6 Unsigned R/W Spare 0
7 Unsigned R/W Spare 0
8 Unsigned R/W RPM_LOW RPM 400
9 Unsigned R/W RPM _HIGH RPM 3200
Tacho
10 Unsigned R/W RPM_CAL 120
Teeth
11 Unsigned R/W OIL_PRESSURE_LOW Kpa 100
Calibration
Unsigned R/W OIL_PRESSURE_CAL 0
12 Table No.
13 Unsigned R/W TEMP_LOW DegC 5
14 Unsigned R/W TEMP_HIGH DegC 110
Calibration
15 Unsigned R/W TEMP_CAL 0
Table No.
16 Unsigned R/W AMPS_CAL *10 mA 100
(10 for
17 Unsigned R/W FUEL_LOW % 70 STOP-
START)
18 Unsigned R/W FUEL_OPTIONS 1
19 Unsigned R/W FUEL_CAL 0
20 Unsigned R/W USER_PASSCODE 2680
21 Unsigned R/W Spare 0
22 Unsigned R/W START_BATT_VOLTAGE_CAL 100
23 Unsigned R/W CONTROL_BATT_VOLTAGE_CAL 100
Offsets
24 Unsigned R/W CHARGER_CURRENT_OFFSET_CAL 0 Fuel Sensor
for Offset

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 caused by
charger
current
25 Unsigned R/W FAN_RUN_ON_CAL Seconds 120
26 Unsigned R/W POWER_FAIL_TIMEOUT Minutes 240
27 Unsigned R/W RELAY_1_OPTION 1
28 Unsigned R/W RELAY_2_OPTION 19
29 Unsigned R/W RELAY_3_OPTION 3
30 Unsigned R/W RELAY_4_OPTION 6
31 Unsigned R/W RELAY_5_OPTION 16
32 Unsigned R/W RELAY_6_OPTION 1
33 Unsigned R/W RELAY_7_OPTION 19
34 Unsigned R/W RELAY_8_OPTION 3
35 Unsigned R/W RELAY_9_OPTION 15
36 Unsigned R/W RELAY_10_OPTION 8
37 Unsigned R/W RELAY_11_OPTION 9
38 Unsigned R/W RELAY_12_OPTION 24
39 Unsigned R/W RELAY_13_OPTION 25
40 Unsigned R/W RELAY_14_OPTION 14
41 Unsigned R/W RELAY_15_OPTION 4
42 Unsigned R/W RELAY_16_OPTION 20
(50 for
43 Unsigned R/W Fuel_level_warning STOP-
70 START)
10
44 Unsigned R/W Alarm_delay
(Seconds)
45..47 Unsigned R/W Spare 0
MAPPED TO ENGINE START
48-63 Unsigned R/W REGISTERS, 0..15
Refer 3

2.1.2 Register 3 - Bitmapped Options

VALUE
BIT PARAMETER OPTION SETTING
( ** Note)
Enable Remote 0=Buttons Inactive (default),
0 1
Buttons 1=Buttons Active
Enable Remote 0=Remote Display Disabled (default)
1 2
Display 1=Remote Display Enabled
0=12V (default)
2 4 System Voltage
1=24V
Differential AtoD for 0=Single Ended AtoD (<Rev C)
3 8
fuel sensor 1=Differential AtoD (Rev D)
0=Normal Fire System
4 16 Stop-Start-System
1=Stop-Start Control

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 Water-Level-Stop- 0=No Shutdown On Low Water Level
5 32
Pump 1= Shutdown On Low Water Level
0=Oil Pressure Normal (Enabled)
5 64 Oil Pressure Disable
1=Oil Pressure Disable

** NOTE: Register Value = Sum of the Values x Option Set

Example – to set options for 24V system with Stop-Start Control and all other options =0, then
Register Value = 4*1 + 16*1 = 20

2.13 Register 27 to 42 - Relay Option

Each relay (1 to 16) can be programmed with a value which will cause the relay to be operated when the
condition is set.
OPTION
OPTION CONDITION
VALUE
0 Relay is NOT operated
1 Mains Power Available
2 Pump Available
3 Pump Running
4 Auto Isolated
5 Failed Start
6 Low Fuel
7 Over Speed
8 High Temp
9 Low Oil Press
10 Start Charger Failed
11 Control Charger Failed
12 Start Batt Low V
13 Control Batt Low V
14 Alarm Muted
15 Low Pressure
16 Water Tank Low
17 Jack Pump Run
18 Jacking Pump Fault
19 Common Fault
Fan Run On
20
(time set in Register 25)
21 Engine Processor Comms Failed
Mains failure – time delay
22
(Delay time set in Register 26)
23 Common Battery / Charger Fault
24 Common Low Battery Fault
25 Common Charger Fault

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 26 Fuel Level Warning
27 Processor Heartbeat Pulse (1 minute)
28 Common Alarm without Pump Run

2.1.4 ENGINE START PROCESSOR Register Descriptions

Holding
Type Access Name Units Comment
Register Default
0 Unsigned R model 13241 13241
10 x version.
1 Unsigned R software version So version 2.7
0 would be 27
2 Unsigned R/W SWITCHES_LATCHED 0 Bit Mapped
3 Unsigned R SWITCHES_CURRENT 0 Bit Mapped
4 Unsigned R PROCESS STATE 0 See Table 2
5 Unsigned R RPM (Period count *8uSec) 0
RPM LOW (Max Period count
6 Unsigned R/W *8uSec 0
*8uSec)
RPM HIGH (Min Period count
7 Unsigned R/W *8uSec 0
*8uSec)
8 Unsigned R/W SPARE 0
9 Unsigned R FLAGS 0
See Table
10 Unsigned R/W COMMAND 0
4.11.4.1
11 Unsigned R OUTPUT STATE – current 0 Bit Mapped
12 Unsigned R/W START DELAY (x100mSec)
13 Unsigned R/W RESTART DELAY (x100msec)
14 Unsigned R/W RUN ON DELAY (x100mSec)
0=RUN
B0- STOP
SOLENOID
15 Unsigned R/W OPTIONS solenoid
1=STOP
Function
SOLENOID

2.1.4.1 Register 4 – CONTROL BITMAPPED REGISTER

BIT DESCRIPTION DESCRIPTION
0 MANUAL RESET
1 MANUAL STOP

16 STOP OVERRIDE STOP/START SYSTEMS

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2.1.4.2 Register 4 – PROCESS STATE
STATE
ABBREVIATED DESCRIPTION
NUMBER
0 STOPPED Normal Idle State
1 WAIT_RESTART
2 CRANKING
3 RUN
4 FORCED_STOP
Alarm Condition –requires
5 STOPPED_OVERSPEED
manual Alarm Reset
Alarm Condition –requires
6 RESTART_LIMIT
manual Alarm Reset
7 MANUAL STOP
STOP-START mode only –
8 STOP OVERRIDE
manual Alarm Reset
9 STOP LOW PRESSURE STOP-START mode only

2.1.5 NOTE ON UPDATING USER CONFIGURATION

For the MAIN PROCESSOR all the read-only registers (3 to 47) stored in EEPROM for the main processor.

For the ENGINE CONTROL PROCESSOR there are 4 registers (12,13,14,15) which are user configurable
(via the main registers 60,61,62,63) and these are stored in EEPROM for the Engine Processor. They can also
be viewed and updated via menus 40 to 43.

NOTE: This means that if a MAIN MODULE (D13242) is replaced then these registers will need to be
checked and updated if necessary.

If the MAIN PROCESSOR MODULE (D1340) is replaced then Registers 3 to 47 will need to be checked and
updated..
The LOAD DEFAULTS menu process should be done initially when the processor is first replaced.
However, this will not change any of the Engine Processor Registers (12,13,14,15) and which are found at
main Registers 60 to 63.

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m. PROGRAMMING MODE
The buttons on the Main Board are used for Programming Mode.

2.m.1 Programming Mode

To enter programming mode – press the buttons in the following sequence.
If the sequence is incorrect, then must start again.

<ESC> <DOWN> <DOWN> <LEFT> <RIGHT> <ENTER>

The display then goes blank with “Prog” displayed in [START BATTERY VOLTS]

2.m.2 Exit Programming Mode

Programming mode will be terminated and the displays returned to normal with any of the following
conditions:-

(1) Timeout - automatically exit programming mode after 60 Seconds without any button press.

(2) Pressing the <ESC> button

(3) Low Pressure input triggers an automatic engine start.

2.m.3 General Button Navigation Conventions

<ENTER> is used to save the current set value.

<ESC> exits program mode

<RIGHT> & <LEFT> are used to scroll through the MENU LEVELS

<UP> <DOWN> are used to Increment or Decrement the Set Value.

NOTE: Press and hold starts increments/decrements UP/DOWN at 1 per second

Press UP and then DOWN – increments x10 at 1 increments per second
Press UP and then DOWN – decrements x10 at 1 increments per second

Holding any of the above conditions for more than 5 seconds, then increments or
decrements at a fast rate (3 per second)

Values should remain within the designated range

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 20

The displays are used in the following way:-

[START BATTERY VOLTAGE] field displays “Prog” while in program mode

[CONTROL BATTERY VOLTAGE / START BATTERY CURRENT] displays the Menu Level
[FUEL LEVEL] displays the current parameter value to be adjusted
[HOURS] is used with the calibration values to display the calculated value in the designated units
E.g. Speed in RPM, Pressure in Kpa, Fuel in %.

NOTE: Enter must be pressed to save the value.

This also updates the [HOURS] field to reflect the current sensor measurement.

2.m.4 Menu Levels

[CONTROL
VOLTS] Display
= [HOURS] Display = [FUEL] Display
MENU LEVEL

0 Main Processor S/w Version

1 Engine Start Processor S/w Version
2 Low RPM Threshold
3 High RPM Threshold
4 Current RPM Cal Value (Flywheel Teeth)
5 Low Oil Pressure Threshold KPa
6 Current Oil Pressure Kpa Cal Table Number
7 Low Temperature Threshold DegC
8 High Temperature Threshold DegC
9 Current Temperature Cal Table Number
10 Current Alternator Amps Cal Value (Shunt Milliohms)
11 Low Fuel Threshold (5 to 95)%
Option
12 Current Fuel Level 0=Low Fuel Switch Only
1=Low Fuel Level Parameter or Low Fuel Switch
13 Current Fuel Level Cal Table Value
14 Fan Run-on Timer Seconds
15 Options – Refer Table 2.l.2
16 Power Fail Time Delay (Minutes)
Set Date and Time
d1 Set Day number
See 4.12.5
d2 Set Month number
d3 Set Year
t1 Set Hours(24Hr)
t2 Set Mins
22 Relay 1 – Option

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 21

 23 Relay 2 – Option
24 Relay 3 – Option
25 Relay 4 – Option
26 Relay 5 – Option
27 Relay 6 – Option
28 Relay 7 – Option
29 Relay 8 – Option
30 Relay 9 – Option
31 Relay 10 – Option
32 Relay 11– Option
43 Relay 12– Option
34 Relay 13 – Option
35 Relay 14 – Option
36 Relay 15 – Option
37 Relay 16 – Option
38 Fuel Level Warning (5 to 95)%
39 Alarm Delay (0 to 300)seconds
40 Engine Start Delay (10 to 3000)*100mSec
41 Engine Restart Delay (100 to 3000)*100mSec
42 Engine Run_on Time (10 to 3000)*100mSec
Engine Processor Options(Bitmapped):
43
B0 – 0= RUN Solenoid, 1=STOP Solenoid
Load ALL Factory Defaults
44
101
Load Default RELAY OPTION
101 = Default Option 1
45 102 = Default Option 2
103 = Default Option 3
104 = Default Option 4

2.m.5 Setting Date & Time

Five numeric displays are used as follows:-
[RPM] = DD (Day number) [TEMP] = HH (Hours – 24Hr)
[HOURS] = MM (Month) [AMPS] = MM (Minutes)
[OIL PRESSURE] = YYYY (year)
As each parameter is selected, the corresponding display flashes.

2.m.6 Setting RPM HI, LO & CAL Values

NOTE: These settings are important to the operation of the ENGINE START PROCESSOR
These settings affect the engine low and hi RPM threshold values.
These in turn can cause the pump engine to be stopped if not set correctly

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 22

The Hi and Lo threshold values are the period counts (units x 8usec) of pulses from a tacho.
The Engine start processor also saves these values to internal EEROM, and so with power up reset will
retrieve the correct values from EEROM.

Note - the main processor saves these values as RPM using the conversions below.
The main processor also saves the CAL value which represents the number of teeth in the flywheel tacho,
which is used in the conversions.

On power-up the main processor to reads the Hi and Lo Period values from the engine start processor and
if not agreed (after conversion) with the RPM values saved in main processor EEROM then an alarm flag is
set
The event will be logged to EEROM and the also the RPM display is set to fast flash.
The alarm is only cleared by the next good power-up reset.

2.m.7 Hour Meter

The Hours Run is saved with a high degree of security.
The Hours Counter is a 32 bit counter and is incremented in 1 second intervals.
The value is saved every 60 seconds that the engine is running (RPM > minimum), plus one more save after it
is stopped.

The displayed HOURS RUN is then the Hours Counter / 360 if the value is <1000*3600 or Hours Counter
/3600 if the Hours Counter is >=1000*3600

EG Displays as “nnn.n” up to 999.9 then “nnnn” for > =1000

Three separate copies of the current value are saved in EEPROM (3 * 4 = 12 bytes)

When reading the values (after power-up) the following rules apply:-

If 2 of the 3 values are matched, then is a valid set and the Hours Counter is set to this value. Any value
which is larger than 10000*3600 is out of range and is not matched
The current value is then written back to EEROM in the 3 copies.

If all 3 values are not matched, then set the Hours counter to 0xFFFFFFFF.
This will then be displayed as 9999 and cause the display to flash.

2.m.8 Load Relay Defaults

The Value field sets the Relay defaults for each of the 16 relays according to the table below.

VALUE 101 – DEFAULTS = {1,19,3,0,0,0,0,0,0,0,0,0,0,0,0,0},

VALUE 102 – DEFAULTS = {1,19,3,0,0,0,0,20,0,0,0,0,0,0,0,0},
VALUE 103 – DEFAULTS = {1,19,3,0,0,0,0,0,0,0,0,0,0,0,0,0},
VALUE 104 – DEFAULTS = {1,19,3,0,0,0,0,0,0,0,0,0,0,0,0,0},

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 23

n. VIEW LOG MODE
The buttons on the Main Board are used to for View Log Mode.

2.n.1 Enter View Log Mode

To enter View Log mode – press the buttons in the following sequence.
If the sequence is incorrect, then must start again.

<ESC> <UP> <DOWN> <LEFT> <RIGHT> <ENTER>

The display then goes blank with “Log” displayed in [START BATTERY VOLTS]

2.n.2 Exit View Log Mode

The View Log Mode will be terminated and the displays returned to normal with any of the following
conditions:-

(1) Timeout - automatically exit programming mode after 2 minutes without any button press.

(2) Pressing the <ESC> button

(3) Low Pressure alarm triggers an automatic engine start.

2.n.3 Operation
<ESC> exits view log mode

<UP > & <DOWN> Scrolls through the event log

<LEFT> Return to the last record

<RIGHT> Skip x10 Records

<ENTER. Delays the alternating display for further 10 seconds

2.n.4 View Log Display

The Display has 2 views.
These views are displayed alternately, 2 seconds with the Log Header View, and 5 seconds with the Status
View.

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 24

2.n.4.1 Log Header View
This displays the record number, date and time in the following fields:-

[START BATTERY VOLTS]= “Log”

[CONTROL BATTERY/START BATTERY AMPS] = Record Number

[RPM] = DD (Day number) [TEMP] = HH (Hours – 24Hr)

[HOURS] = MM (Month) [AMPS] = MM (Minutes)

[OIL PRESSURE] = YYYY (year)[FUEL TANK LEVEL]= Seconds

2.n.4.2 Status View

The status displays the same as it was just after the event was logged.

o. DATA LOGGING
Logged data is saved to 32KB EEPROM

2.o.1 Status Log

The system logs a status record that contains
FIELD DESCRIPTION NOTES
NUMBER
1 Record Number
2 Date YYMMDD
3 Time HHMMSS
4 State of All Digital Input Bitmapped
5 State of Indicators Bitmapped
6 Engine Hours
7 Engine RPM
8 Oil Pressure
9 Engine Temperature
10 Alternator Amps
11 Fuel Level
12 State of Outputs
Control Battery Volts FIRE SYSTEM ONLY
Control Charger Amps FIRE SYSTEM ONLY

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 25

 Start Battery Volts
Start Battery Charger Amps
Engine Start Processor State
Relays Operated Bitmapped
Flags Bitmapped
A status record is logged every time any of the following happen.
1. Whenever a digital input or output changes state
2. When internal status flags are changed:-
BOOT
BAD_RPM_LIMITS
MUTE
LOW_FUEL_WARNING
OVERSPEED
AUTO_ISOLATED
LOW_WATER_PRESSURE
ENGINE_STABLE
ENGINE_CONTROLLER_FAILED_RESTART_LIMIT
ENGINE_CONTROLLER_COMMS_FAILED
SUPPLY_CRITICAL_ALARM
CONTROL_CHARGER_FAIL
CRANK_CHARGER_FAIL
MAINS_FAILED

ENGINE_SHUTDOWN

3. Every 1 hour
4. Every 1 minute when the pump is running or pressure switch is on
5. Whenever the unit is placed in configuration mode or returned to operating mode.

The unit can store 250 status records in a circular store. The last 250 records are kept with the oldest
record being written over first.

2.o.2 Configuration Log

The system logs a configuration record containing a complete copy of the new configuration whenever a
system is restarted after changing the configuration. The unit can store 50 configurations.

By keeping the configurations it is possible to know how the controller was configured at any time. This is
useful for interpreting the status log.

BYTE NUMBER FIELD NOTES

0 .. 1 Record Number
2 .. 5 Time & Date 32bit universal time
Copy of all Main Processor
6 .. 57
Registers in section 4.7

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 26

p. DIAGNOSTIC PORT
An RS232 port is available for Programming and Diagnostics and allows the following:-

(1) View and setting (where writable) Main Processor registers in 4.10.1
(2) Viewing and setting (where writable) Engine Start Processor registers via the Modbus protocol
(3) Download of the Logged data.
(4) Viewing the Current Status and Engine Instrumentation data.

It uses an ASCII protocol with a simple command set (see table below)

The port is set up with the following fixed serial parameters:-

Speed 115200 Baud
Data Bits 8
Parity None
Stop Bits 1
Handshake None

2.p.1 Passcode Access

The diagnostics port requires entry of a USER PASSCODE (Default is 2680) before can access functions.

NOTE: - this feature is NOT currently activated.

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 27

2.p.2 Commands
Commands are entered as ASCII Numeric Fields
The First field is the Command number
This is followed by 1 or 2 arguments as ASCII representing 16 bit signed integers
Fields are separated by space and line ends in <CR>
FUNCTION
ARGUMENT 1 ARGUMENT 2 DESCRIPTION
NUMBER
View Register
1 Register Number 0..31 for Local Registers
32..43 for Engine Start Registers
Set Register
2 Register Number Value 0..47 for Local Registers
48..59 for Engine Start Registers
3 Register Number View Display Register
Set Display Register.
Note – will need to be in test
4 Register Number Value
mode as value will be overwritten
in normal mode
View Current Display Panel Data
5 (Same format as Log data) CSV
format
Dump Status Log
If Record number End =0 or not
entered, then set to Last (most
6 Record Number Start Record Number End
Current) record.
Set the view record pointer to
Record Number End
View Status Log Record at record
0=Current pointer. In Test Mode then the
7 1=Previous display will also show the display
2=Next status values for the logged
record.
Dump Configuration Log
If Record number End =0 or not
entered, then set to Last (most
Current) record.
8 Record Number Start Record Number End
Set the view record pointer to
Record Number End
If no arguments, then Dump ALL
records
View Configuration Log Record at
0=Current record pointer. In Test Mode then
9 1=Previous the display will also show the
2=Next display status values for the logged
record.

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 28

 10 Dump Configuration Registers.
See Note ** below
14 Read Clock
15 Set Clock
DD MM YY HH MM SS
Note – 24HR TIME
17 Show Calibration Values

18 A/d Register No Display RAW a/d value

19 Reset to Factory Default
3781
Parameters

2.p.3 Responses
All Responses (Except for command 10) are as follows:-
XXX (s) YYYYY
Where XXX is the Response Number = Command Number +100
(s) YYYYY is 1 to 5 digits representing the (signed) integer value
If a command has incorrect syntax or fields are out of range, then the invalid response is
255 NNN
Where NNN is the error number
ERROR NUMBER DESCRIPTION
1 Invalid Command
2 First Argument Invalid
3 Second Argument Invalid
4 Both Arguments Invalid

2.p.4 Function 5 – View Current Status

The command 5 returns a comma separated (CSV) line showing the current status of the indicators, engine
instrumentation and other internal parameters.
An example is as follows:-
105,42,3783620755,3456,64095186,1078,2981,0,999,0,0,0,202,0,0,0,3,2
The 18 fields shown are:-
FIELD PARAMETER DESCRIPTION
0 Response code (105)
1 Record_number Record Sequence number
Time in universal time - Seconds since
2 Time
0:00:00 0/0/2000
3 Digital_inputs Bitmapped field – see 2.p.4.1
4 Indicators Bitmapped field – see 2.p.4.2
5 Engine_hours Engine Running time in seconds
6 Engine_rpm Engine Speed

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 29

 7 Engine_oil_pressure Engine Oil Pressure - Kpa
8 Engine_temperature Engine Temperature – DegC
9 Alternator_amps Alternator Amps x 10
10 Engine_fuel_level Fuel Level - %
11 Digital_outputs Bitmapped field-
12 Control_battery_volts Voltage x10
13 Control_battery_amps Amps x10
14 Start_battery_volts Voltage x10
15 Start_battery_amps Amps x10
16 Engine_start_state Engine Processor State – see 2.p.4.3
17 Relays Bitmapped State for each of the VFC Relays
18 Flags Main Process Flags – see 2.p.4.4

2.p.4.1 Digital Inputs – BITMAPPED Field

BIT POSITION D13242 FUNCTION
P_DIN0 Not Used
P_DIN1 MUTE EXTERNAL J10
P_DIN2 CONTROL MAINS FAIL
P_DIN3 AUX INPUT J9
P_DIN4 CRANK MAINS FAIL
P_DIN5 AUX INPUT J8
P_DIN10 MANUAL CONTROL SWITCH
P_DIN11 MANUAL START SWITCH
P_DIN12 STOP
P_DIN13 FUEL SWITCH
P_DIN14 Not Used
P_DIN15 LOW PRESSURE

2.p.4.2 INDICATORS – BITMAPPED field

REFER TABLE e for further descriptions
Bit Position LED Function
Position
0 D10 Pump Available
1 D11 Pump Running
2 D12 Auto Start Isolated
3 D13 Engine Fail to Start
4 D14 Low Fuel Level
5 D15 Engine Overspeed Shutdown
6 D16 High Engine Temperature
7 D28 Low Oil Pressure
8 D17 Control Battery Charger Fail

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 30

 (FIRE SYSTEM ONLY)
9 D18 Start Battery Low Voltage
10 D19 Control Battery Low Voltage
(FIRE SYSTEM ONLY)
11 D20 Audible Alarm Muted
12 D21 System Low Water Pressure
13 D22 Water Supply Tank Low Level
14 D23 AUX 1
15 D29 Power Available
16 D30 AUX 2
17 D31 Start Battery Charger Fail

2.p.4.3 Engine Processor State

STATE
ABBREVIATED DESCRIPTION
NUMBER
0 STOPPED Normal Idle State
1 WAIT_RESTART
2 CRANKING
3 RUN
4 FORCED_STOP
Alarm Condition –requires
5 STOPPED_OVERSPEED
manual Alarm Reset
Alarm Condition –requires
6 RESTART_LIMIT
manual Alarm Reset
7 MANUAL_STOP

2.p.4.4 Main Process Flags

BIT POSITION ABBREVIATED DESCRIPTION
The unit has been reset –
0 BOOT Cleared with the first logged
record
Engine Processor RPM Limits do
1 BAD_RPM_LIMITS not match the main processor
RPM Limits
2 MUTE Alarms are muted
3 SPARE1
The unit is tripped out with
4 OVERSPEED
overspeed
5 AUTO-ISOLATED Unit is in auto-isolate mode
6 LOW FUEL WARNING
7 LOW WATER PRESSURE
8 ENGINE STABLE
ENGINE CONTROLLER FAILED
9
RESTART LIMIT

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 31

 ENGINE CONROLLER COMMS
10
FAILED
11 SUPPLY CRITICAL FAILURE Loss of Mains for 4 Hours
12 CONTROL CHARGER FAILED
13 CRANK CHARGER FAILED
14 MAINS FAILED
STOP/START system forced
15 ENGINE SHUTDOWN
shutdown

2.p.4.5 Digital Output

2.p.5 Configuration Register Dump

Note ** - The configuration Register Dump (Command 10) response should be in the following format:-
Example:

D1324 Register Dump (header 1)

dd/mm/yyyy hh:mm:ss (header 2)
2 0 13401 (first Local register)
2 1 12 (second register)
2 2 1
2 3 1
“ “ “
“ “ “
2 47 0 (last Local Register)
2 48 13241 (first Engine Start register 0)
“ “ “
“ “ “
2 59 0 (last Engine Start register 11)

The register fields are commenced each line with ‘2’

This allows the text to be captured to a file with Hyperterm
This file can then be modified and then sent back to the main processor

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 32

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 33
 A
APENDIX A
Warranty and Service Information

ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 34

 alliedpumps.com.au
alliedpumps.com.au

Disclaimer: Allied Pumps reserves the right to modify the information and illustrations contained in this document without prior notice. The information
provided in this document is intended to be helpful. However, this document is not intended to cover all regulations that apply to your practice. If you need
ALLIED PUMPS PYROKOS PUMP CONTROL SYSTEM MANUAL | 35
advice regarding specific product operations and maintenances, you are encouraged to consult with an Allied Pumps Pty Ltd professional.