CLA-VAL PC-1 User manual

INTRODUCTION
Thank you for purchasing Cla-Val
Model PC-1 Pump Control Panel.
The Cla-Val Model PC-1 Pump
Control Panel (P/N 2444901K) pro-
vides electrical interlock control
between Cla-Val Pump Control
Valve and pump with simple field
hook-up and easily adjusted pump
starting and stopping sequence
steps. It is suitable for Booster
Pump and Deep Well Pump appli-
cations. For detailed operation
information see Cla-Val engineering
data sheet E-PC-1 included with
this manual.
SAFETY
The PC-1 is made by a UL Listed fabricator File No. E 134765.
This means the PC-1 is made to the highest electrical standards
available (UL Category 508 Industrial Control Panels).
Personnel installing or using this equipment should read entire
manual (and any other included documents) to become familiar
with requirements for installing or operating the PC-1. At a mini-
mum, you should follow all applicable sections of the National Fire
Code, National Electrical Code, and National Electrical
Manufacturer’s Association Standards. There may be local regu-
latory or governmental offices that can also help determine which
codes and standards are necessary for safe installation and oper-
ation.
INSTALLATION
The installation should provide proper ventilation, spacing, and
grounding techniques to help minimize the risk of potential prob-
lems. Recommended mounting of the PC-1 is on vertical surface
at a convenient location near pump motor panel. Conduit should
be routed to the bottom of enclosure for easy hook-up to internal
field wiring terminal strip. Use appropriate size hole saw to cut only
the required number of holes in enclosure bottom. In order to
maintain the watertight integrity of the enclosure, only watertight
conduit connectors should be used.
WIRING
Consider the following wiring guidelines before you install any sys-
tem or power wiring. For specific information on wiring, refer to
product specification sheet or National Electrical Code require-
ments. There may be local regulatory or governmental offices that
can also help determine which codes and standards are necessary
for safe installation and operation.
• Always use continuous length of wire. Do not combine wires
to attain a needed length.
• Use the shortest practical cable length.
• Avoid running wires near high energy wiring.
• Avoid running input wiring in close proximity to output wiring
where possible.
• Avoid creating sharp bends in the wires.
Input Power
Provide 5 amp fused 120/60 VAC input power for PC-1 at terminals
1 and 2. Provide protection from AC power voltage spikes, elec-
tro-magnetic interference (EMI), and lightning strikes according to
all applicable electrical wiring codes. Be sure to properly connect
earth ground to green terminal.
Noise Suppression
AC power voltage spikes, electro-magnetic interference (EMI),
lightning strikes, and AC-powered solenoids coil activation create
electrical "noise" that can affect PC-1 controller operation. Noise
suppressors are necessary for optimum PC-1 operation. MOV
noise suppressors should be installed on PC-1 power input at ter-
minals 1 and 2 and on power (red) wires of valve solenoid(s) as
close to the solenoid coil as practical. Cla-Val offers an optional
Noise Suppressor (p/n 2696336D) rated RC Snubber (MOV-type),
250 VAC, 70 Joules, one-piece with tinned leads.
FUSES
The PC-1 is supplied with
four fuses for the powered
output circuits. They are
found in fuse holders
marked F1, F2, F3, and
F4. Prior to replacing any
fuse all power to the PC-1
must be turned off.
Replace fuses with 10 mm
x 0.38 mm fuses of the
proper current rating.
• Fuse F1 is rated 10 A and is on NON-POWERED Pump Motor
Start Command Circuit
• Fuse F2 is rated 1A and is on Valve E-Stop Solenoid Output
Circuit
•Fuse F3 is rated 1A and is on Valve Pilot Solenoid Output
Circuit
• Fuse F4 is rated 1A and is on Loss of Power Restart Delay
Alarm Output Circuit
INPUTS
The PC-1 control inputs are:
MANUAL/LOCAL START
To initiate a pump start, place the H-O-A switch in Hand position
and press the green Start switch. Pump will continue to run until
red Stop switch is pressed to initiate a normal pump shutdown.
When H-O-A switch is in Off position the PC-1 will not initiate a
start sequence manually (local) or automatically (remote).
AUTOMATIC/REMOTE START
To initiate a pump start, the PC-1 receives a pump start signal from
a remote source such as a SCADA controlled RTU panel or a pres-
sure switch. With the H-O-A switch in Auto a contact closure will
initiate a pump start. Pump will continue to run while contacts are
closed. Contact opening or positioning the H-O-A switch to Off will
initiate a normal pump shutdown.
PC-1
Pump Control Panel
MODEL
INSTALLATION / OPERATION / MAINTENANCE

VALVE LIMIT SWITCH
The Normally Open and Common contacts of pump control valve
limit switch are used for signaling valve position to the PC-1.
These contacts are closed when valve is closed (or when valve is
open for deep well pumps). The valve limit switch is adjusted to
actuate when the valve is in closed position (or open for deep well
pumps). For valve switch adjustment procedure, see Cla-Val
Model X105L Valve Limit Switch Assembly data sheet in technical
manual for pump control valve.
DISCHARGE PRESSURE SWITCH
In order to use the pressure-related functions of the PC-1, an
optional customer supplied pressure switch must be installed
between pump discharge and control valve inlet. The Normally
Open contacts of the pressure switch are used (contacts close
when pressure setting is reached or exceeded). If a pressure
switch is not used, a factory supplied jumper must be installed
across terminals 9 and 10. Remove jumper when installing pres-
sure switch.
ANTI-PLUGGING PUMP SWITCH
Some pumps have built-in contacts to indicate pump motor shaft is
rotating (forward or backward) when no electric power is applied.
These Anti-Plugging Pump Contacts are used for signaling to the
PC-1 that pump is rotating. These contacts are closed when pump
is rotating and keep PC-1 from initiating a start sequence and
potentially causing pump damage.
LAMP TEST/ALARM RESET SWITCH
Momentarily pushing of this switch will test all indicator lamps
when power is on (they will all light while the switch is depressed).
A 5 to 10 second push of this switch will reset (or acknowledge)
any alarm light signal and all lights will go off (white light remains
on). If the alarm condition is not corrected after acknowledgment
by this switch, the alarm will again trip.
EMERGENCY STOP SWITCH
This push-pull, snap-action switch will remove all power to PC-1
outputs when pushed IN. The internal PLC remains powered.
When switch is pulled OUT the PC-1 will operate normally. The
switch must "click" into place. Activating this switch requires a
heavy manual force.
OUTPUTS
The PC-1 control outputs are:
1. Valve Pilot Solenoid Output Control Circuit (120/60 VAC
powered)
2. Valve E-Stop Solenoid Output Control Circuit (120/60 VAC
powered)
3. Pump Motor Start Command Circuit (non-powered but
fused)
4. Failure to Develop Pressure Remote Alarm Output Circuit
(non-powered)
5. Loss of Pressure Remote Alarm Output Circuit (non-
powered)
6. Valve Failed to Open Remote Alarm Output Circuit (non-
powered)
7. Valve Reclosed Remote Alarm Output Circuit (non-powered)
8. Loss of Power Restart Delay Alarm Output Circuit (120/60
VAC powered)
9. H-O-A Switch in Auto Position Remote Contacts Output
Circuit (non-powered)
TIMERS
The PC-1 is supplied with three field adjustable timers. These
timers provide easy-to-set adjustment of pump start sequence
steps. In case of mechanical trouble with pump, control valve, or
system, these timers keep PC-1 from completing a start sequence.
Timer T1 is LOSS OF POWER AUTOMATIC RESTART DELAY
TIMER. After a loss of power, an automatic pump restart will occur
upon the expiration of timer T1 provided that:
a. The H-O-A switch is in Automatic
b. A signal is present to start the pump remotely (terminal 12 and 13)
c. The valve indicates closed (via valve position switch at
terminals 10 and 11)
NOTE: Automatic restart is disabled by removing jumper from ter-
minals 14 and 15.
Timer T2 is PRESSURE DELAY SEQUENCE TIMER (PDST).
Upon initiation of a pump start command, the PDST is energized.
The pilot valve solenoid is energized upon expiration of the PDST.
In booster pump applications, this time maybe used to allow the
pump to develop discharge pressure before opening the pump
control valve. In deep well pump applications, the time may be
used to flush the system prior to closing the valve and placing the
pump on the system.
Timer T3 is VALVE SEQUENCE TIMER (VST). The VST is ener-
gized when the pilot valve solenoid is energized. If the valve fails
to open (close for deep well pumps) prior to the VST expiring, an
automatic shutdown will occur.
SETTING TIMERS T1, T2, and T3
The Cla-Val PC-1 Pump Control Panel is supplied with three field
adjustable timers (time delay relays) marked T1, T2, and T3. After
setting desired time delay, during the pump start sequence power
is applied to relay coil and control contacts remain open and power
(PWR) light is on. After preset time has elapsed, relay shifts to
close contacts and out (OUT) light is on. Reset occurs when
power is removed by PLC inside PC-1.
There have been three different styles of time delay relays used for
T1, T2, and T3. Each style of relay has different setting instruc-
tions depending on date of PC-1 manufacture.
A. Prior to January 1998, the timers were an orange cube-style
(Syrelec Model OAR2U delay on make) with an adjustable range
of 0.1 sec to 10 hours and used these instructions for setting time
delay.
1. Select Hours, Minutes, or Seconds with the Time Base
Selection Switch on the lower right-hand front. Use a small
screwdriver (4 mm maximum width) to move switch up or
down and view desired setting in window above switch.
Make sure switch clicks or snaps into place.

2. Select desired multiplier (x0.1 or x1) by moving Scale
Selection Switch located to the left of the time base switch.
Make sure switch clicks or snaps into place.
3. Rotate Dial (for 0 to 10 units) to desired time delay setting
within the Time Base range and Scale multiplier selected.
B. Between January 1998 and January 2004, the timers were a
blue cube-style (IDEC Model RTE-P12) and used these instruc-
tions for setting time delay.
1. Select desired maximum time range using only Time Range
Group 2in following table. Table is also on bottom side of
relay. M= minutes, H= hours
2. Remove thin plastic dial faceplate. Use a small screwdriver
(4 mm maximum width) under lip at bottom center to
carefully pry faceplate off relay top. Do not remove knob.
3. Digital Switch is located on lower left corner of relay top face.
Adjust digital switch up or down with a small screwdriver until
desired time range number is displayed in window.
4. Mode of Operation switch is located on upper left corner of
relay top face. This switch must be kept in the right-hand
position for "Delay on Make" operation.
5. Rotate inner portion of plastic dial faceplate until desired
time range and units show in faceplate windows. You may
have to turn plastic dial over to find desired range and to
match dial color. Refer to above chart. Reinstall plastic dial
on top of relay by inserting top edge tabs into top slots.
Bend the dial faceplate slightly as it is placed over knob and
insert the bottom edge into the bottom slot of the timer. As
dial faceplate "snaps" into place at the top, make sure that
inner dial remains in place.
6. Use center knob to set amount of time delay desired within
the range selected.
C. Starting in January 2004, the timers were changed to a blue
cube-style (IDEC Model RTE-P1AF20) and use these instructions
for setting time delay.
1. Select desired time range using following table. Set Time
Range Selector and Dial Selector at bottom of relay face to
corresponding positions for desired time range. Use a small
screwdriver (4 mm maximum width) to turn selectors. Make
sure switch clicks or snaps into place. DO NOT FORCE
BEYOND END POSITION.
2. Mode of Operation switch is located on lower left corner of
relay top face. This switch must be kept in the ”A” mode
position for "Delay on Make" operation.
3. Use center knob to set amount of time delay desired within
the range selected.
FIELD WIRING HOOKUP TERMINALS
The following describes the input and output terminals of PC-1
panels built since January 1996. Refer to Field Wiring Hookup dia-
gram Cla-Val drawing 204377 included with this manual.
A.) Terminals 1, 2 and Ground are for connecting 120 Volt 60Hz
AC (5 Amp fused) power (customer supplied). This is for
power to the PC-1 itself. Terminal 3 is NOT used.
B.) Terminals 4 and 5 are dry-contacts (N.O. rated: 120 VAC, 10
Amp - fused at F1) for connection to customer supplied
pump motor starter circuit.
C.) Terminals 6 and 7 have 120 Volt AC power (up to 1 Amp -
fused at F2) present (the PC-1 will energize these when
needed) and are to be connected to the Emergency Closing
Solenoid on the control valve (if present).
D.) Terminals 7 and 8 have 120 Volt AC power (up to 1 Amp -
fused at F3) present (the PC-1 will energize these when
needed) and are to be connected to the Pilot Valve Solenoid
on the control valve.
E.) Terminals 9 and 10 are dry-contact type (24 volt DC, 10
Milliamp) for connection to customer supplied no-voltage
circuit to Pressure Switch (N. O. contact and Common
contact) located between pump output and valve inlet (if
present).
F.) Terminals 10 and 11 are dry-contact type (24 volt DC, 10
Milliamp) for connection to customer supplied no-voltage
circuit to Cla-Val Model X105L Valve Limit Switch (N. O.
contact and Common contact) mounted on the valve.
G.)Terminals 12 and 13 are dry-contact type (24 volt DC, 10
Milliamp) for connection to customer supplied no-voltage
circuit to provide Remote/Automatic Start with the PC-1.
When these contacts are "made" and with the H-O-A switch
in Automatic, the PC-1 will initiate a start of the pump and
continue to allow the pump to run until this contact is broken.
H.) Terminals 14 and 15 are for allowing automatic Loss of
Power Restart with the jumper installed (standard). PC-1
will automatically initiate a pump start after power is
restored. If the jumper is not present, the PC-1 will not
initiate a pump start when power is restored after a loss of
power. A manual reset with the Lamp Test/Reset switch
(30-sec. minimum) will be needed to restart the pump after
power is restored.
J.) Terminals 16 and 17 are dry-contact type (N.O. rated: 1
Amp, 120 VAC) for connection to customer supplied circuit
Digital Switch
Position
Time Range Group Dial Color
12
0, (or 8) 1 S 1 M Blue
1, (or 9) 3 S 3 M Violet
26 S 6 M Violet
310 S 10 M Blue
460 S 60 M Violet
530 S 30 M Violet
65 M 5 H Blue
710 M 10 H Blue
Range 0 - 1
scale
0 - 3
scale
0 - 10
scale
0 - 30
scale
0 - 60
scale
s0.1 s-1 s 0.1 s-3 s 0.2 s-10 s 0.6 s-30 s 1.2 s-60 s
min 1.2 s-1 m 3.6 s-3 m 12 s-10 m 36 s-30 m 1.2 m-60 m
h1.2 m-1 h 3.6 m-3 h 12 m-10 h 36 m-30 h 1.2 h-60 h
10 h 12 m-10 h 36 m-30 h 2 h-100 h 6 h-300 h 12 h-600 h
s = seconds, m = minutes, h = hours

for remote signal alarm of Failure To Develop Pressure.
K.) Terminals 18 and 19 are dry-contact type (N.O. rated: 1
Amp, 120 VAC) for connection to customer supplied circuit
for remote signal alarm of Loss Of Pressure.
L.) Terminals 20 and 21 are dry-contact type (N.O. rated: 1
Amp, 120 VAC) for connection to customer supplied circuit
for remote signal alarm of Valve Fail To Open.
M.)Terminals 22 and 23 are dry-contact type (N.O. rated: 1
Amp, 120 VAC) for connection to customer supplied circuit
for remote signal alarm of Valve Re-Closed during start
sequence.
N.) Terminals 24 and 25 have 120/60 AC power (N.O. up to 1
Amp - fused at F4) present when an alarm condition exists
and are for connection to customer supplied circuit for
remote signal alarm of Loss Of Power Restart Delay.
Typically, this would activate a relay for the alarm signal.
O.)Terminals 26 and 27 are dry-contact type (N.O. rated: 1
Amp, 120 VAC) for connection to customer supplied circuit
for remote signaling of the H-O-A switch being in the "Auto"
position. When the H-O-A switch is in the "Auto" position,
no power contact is "made" at these terminals.
P.) Terminals 28 and 29 are dry-contact type (24 volt DC, 10
Milliamp) for connection to customer supplied no-voltage
circuit to provide an "Anti-Plugging" input signal from the
pump (if so equipped) when the pump is coasting or spinning
in reverse. When these contacts are "made" from the pump,
a start sequence will not be allowed.
OPERATION CHECK OUT AND BENCH TEST
The following steps are for a PC-1 operation check out and bench
test. This test is for newer PC-1 panels built since January 1998
and that have on the lid face the following: a) Lamp-test/Reset
switch, b) H-O-A switch mounted to the left-of-center, c) lid has red
and blue color markings on white background, and d) inside the
PC-1 is an Automation-Direct brand modular-style PLC. PC-1’s
built before September 1996 used an Omron brand dedicated PLC
for internal control sequencing and does not follow this sequence
exactly.
Preparation:
A.) PC-1 hooked up to 120/60 VAC at terminals 1, 2, and Ground.
B.) No other inputs or outputs hooked up to the PC-1.
C.) Set Time Delay Relays TR1, TR2, and TR3 to zero time.
D.) H-O-A switch is in OFF position.
The following steps occur when power is applied:
1. On the lid, the white panel light (Power) goes on.
2. On the inside, the CPU module PWR and RUN green
indicators go on.
3. On the inside, the Input module red indicators A0, A7, and
B0 go on (use A/B selector switch to switch between A and
B series).
4. On the inside, the TR1 relay ON and OUT lights are on.
NOTE: If the white panel light does not go on, then the E-STOP
switch is depressed. Lifting the E-STOP switch will turn on white
panel light. The switch must "click" into place.
NEXT, turn the H-O-A switch from OFF to HAND, then push green
(Start) button. Watch for:
1. On the lid, the blue panel light (Pressure) goes on and about
three seconds later the green panel light (Valve Open) goes on.
2. On the inside, the Input module red indicator lights A3, A5,
A6, A7, B0, and B4 go on.
3. On the inside, the TR1, TR2, and TR3 relay ON and OUT
lights go on.
4. On the inside, the CR1 relay red indicator light goes on.
NOTE:
a) To verify that panel lamps are functionary properly, depress
and hold Lamp Test/RESET button. All five panel lights g o
on for about three to five seconds and then go off.
b) If the amber panel light (Restart/Delay) flashes, then
depress the Lamp Test/RESET button for at least 30
seconds to reset the PC-1. You may hear some relay
clicking from inside the PC-1, this is normal. If AC power
to terminals 1, 2, and ground are removed for 30 seconds,
the PC-1 will also reset.
c) If the Lamp Test/RESET button is released before complete
reset, then when the HOA switch is turned from OFF to
HAND (or if it was already in HAND), AND then Start button
is pushed, the amber panel light will flash. A complete 30
second reset will turn off flashing amber panel light.
d) If the Lamp Test/RESET button is released before complete
reset and the amber panel is flashing, THEN when the E-
STOP switch is depressed and then lifted, the red panel
light goes on and the amber panel light will continue to flash.
A complete 30 second reset will turn off red panel light and
flashing amber panel light.
CLA-VAL
Copyright Cla-Val 2006 Printed in USA Specifications subject to change without notice.
P.O. Box 1325 •Newport Beach, CA 92659-0325 •Phone: [phone] •Fax: [phone] •E-mail: [email protected] •Website cla-val.com
©
N-PC-1 (R-8-06)

Cla-Val PC-1 OPERATION SEQUENCE CHART
White Blue Green Amber Red Alarm Pilot Emergency
Input
Power
Pressure
Valve OPEN
Restart Delay
Alarm
Contact
Solenoid
Solenoid
Valve **
Pump
120 VAC Power Available ON OFF OFF OFF OFF n/a De-Energized De-Energized Closed OFF
Pump Start Initiated (Manual or Remote) and Waiting for Discharge
Pressure (Jumper INSTALLED at 9 -10 = skip waiting) *
Pressure
Switch * ON Flashing OFF OFF OFF n/a De-Energized De-Energized Closed Starting
Discharge Pressure Available and Waiting for PDST to Time OUT
Timer
T2 ON ON OFF OFF OFF n/a Energized Energized Opening ON
PVST Energized and Waiting for Valve to Indicate OPEN **
Valve
Switch ON ON Flashing OFF OFF n/a Energized Energized Open ON
Pump Running and Valve OPEN ** ON ON ON OFF OFF n/a Energized Energized Open ON
Pump Stopping Initiated
(Manual STOP or Remote contacts 12-13)
Contacts
12-13 ON ON ON OFF OFF n/a De-Energized De-Energized Closing ON
PVST De-Energized and Waiting for Valve to Indicate CLOSED **
Valve
Switch ON ON OFF OFF OFF n/a De-Energized De-Energized Closing ON
Valve Closed ** and Pump Stopped
Valve
Switch ON OFF OFF OFF OFF n/a De-Energized De-Energized Closed OFF
PDST Expired - Pump failed to develop discharge pressure on STARTUP
(REQUIRES Manual RESET for Restart)
Timer
T2 ON Flashing OFF OFF Flashing
1 Amp DRY @
Contacts 16-17 De-Energized De-Energized Closed Stopping
Loss of Pump Discharge Pressure During Operation
(REQUIRES Manual RESET for Restart) *
Pressure
Switch * ON ON OFF OFF Flashing
1 Amp DRY @
Contacts 18-19 De-Energized De-Energized Closing Stopping
VST Expired and Valve Failed to OPEN ** on Startup
(REQUIRES Manual RESET for Restart)
Timer
T3 ON OFF Flashing OFF Flashing
1 Amp DRY @
Contacts 20-21 De-Energized De-Energized Closed Stopping
Valve Closed WITHOUT Command During Operation
(REQUIRES Manual RESET for Restart)
Valve
Switch ON OFF ON OFF Flashing
1 Amp DRY @
Contacts 22-23 De-Energized De-Energized Closing Stopping
Loss of Power - Automatic RESTART DELAY
(Allows Automatic Reset and Restart) Jumper IN
Timer
T1 ON OFF OFF Flashing OFF
120 VAC powered
Contacts 24-25 De-Energized De-Energized Closing Stopping
Loss of Power - Automatic RESTART DELAY DISABLED
(REQUIRES Manual RESET for Restart) Jumper OUT
Jumper
14-15 ON OFF OFF ON OFF
120 VAC powered
Contacts 24-25 De-Energized De-Energized Closing Stopping
E-Stop Switch DEPRESSED
(all outputs are off and power still present)
E-Stop
Switch OFF OFF OFF OFF OFF n/a De-Energized De-Energized Closing Stopping
* OPTION: Requires Customer supplied Pressure Switch (N.O.)
at contacts 9 -10 in place of factory jumper
** Valve action shown for BOOSTER PUMP applications. Valve action is reversed for DEEP
WELL PUMP applications. PC-1 Electrical INTERLOCK action remains the same.
OUTPUTPanel Light IndicationOperation
PUMP OFF
PUMP STARTING SEQUENCE
PUMP STOPPING SEQUENCE
ALARM CONDITIONS
Prepared by Bob Haines 8/8/2005 Page 1

Typical Booster Pump Application and PC-1 Wiring
Water Flow to System
Booster
PUMP
60 Series
Control Valve
Pump
MOTOR
STARTER
H-O-A
Radio I/O
RTU
H-O-A
Relay
Radio
2
S2 (COM)
1
1
S1 (N.O.) V2V1
2 4 5 7 8 10 11 1312
G
Cla-Val PC-1
120 VAC
1R
L
H
N
1 2
Pump Panel 120 VAC
SCADA
Center
Prepared by Bob Haines 3/30/2007 Page 1

Typical Deep Well Pump Application and PC-1 Wiring
Water Flow to System
Well
PUMP
Check Valve
61
Series
Control
Valve
Pump
MOTOR
STARTER
H-O-A
Radio I/O
RTU
H-O-A
Relay
Radio
2
S1
(
N.O.
)
1
1
S2 (COM)
V1
V2
2 4 5 7 8 10 11 1312
G
Cla-Val PC-1
120 VAC
SCADA
Center
1R
To
Waste
120 VAC
Pump Panel
L
H
N
1 2
Page 2Prepared by Bob Haines 3/30/2007