CLA-VAL PC-22D Instruction manual

PC-22D
Electronic Pump Controller
Installation
Maintenance
Manual
Operation

All measures have been taken to ensure accuracy and completeness of this document. However, as errors can
never be fully excluded, we always appreciate any information or suggestions for improving the document.
E-Mail: [e-mail]
We wish to point out that the software and hardware terms as well as the trademarks of companies used and/or
mentioned in the present manual are generally protected by trademark or patent.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 1
LIMITED WARRANTY
Automatic valves and controls as manufactured by Cla-Val
are warranted for one (1) year from the date of shipment
against manufacturing defects in materials and workmanship
which develop in the service for which they are designed,
provided the products are installed and used in accordance
with all applicable instructions and limitations as issued by
Cla-Val.
We will repair or replace defective material, free of
charge, which is returned to our factory, transportation
charges prepaid, provided that, after inspection, the material
is found to have been defective at time of shipment. This
warranty is expressly conditioned on the purchaser’s giving
Cla-Val immediate written notice upon discovery the defect.
Components used by Cla-Val but manufactured by others
are warranted only to the extent of that manufacturer’s
guarantee.
This warranty shall not apply if the product has been altered
or repaired by others, and Cla-Val shall make no allowance
or credit for such repairs or alterations unless authorized in
writing Cla-Val.
TERMS OF SALE
Acceptance of orders
All orders are subject to acceptance by our main office at
Newport Beach, California.
Credit Terms
Credit Terms are net thirty (30) days from date of invoice.
Purchase Order Forms
Orders submitted on customer’s own purchase order
forms will be accepted only with the express understanding
the no statements, clauses, or conditions contained in said
order form will be binding on the Seller if they in any way
modify the Seller’s own terms and conditions of sales.
Product Changes
The right is reserved to make changes in pattern, design, or
materials when deemed necessary, without prior notice.
Prices
All prices are F.O.B. Newport Beach, California, unless
expressly stated otherwise on our acknowledgment of
the order. Prices are subject to change without notice.
The prices at which any order is accepted are subject to
adjustment to the Seller’s price in effect at the time of
shipment. Prices do not include sales, excise, municipal,
state or any other Government taxes. Minimum order charge
$75.00.
DISCLAIMER OF WARRANTIES AND LIMITATIONS
OF LIABILITY
The foregoing warranty is exclusive and in lieu of all other
warranties and representations, whether expressed, implied,
oral or written, including but not limited to any implied
warranties of merchantability or fitness for a particular
purpose. All such other warranties and representations are
hereby cancelled.
Cla-Val shall not be liable for any incidental or consequential
loss, damage or expense arising directly or indirectly from
the use of the product. Cla-Val shall not be liable for any
damages or charges for labor or expense in making repairs
or adjustments to the product. Cla-Val shall not be liable for
any damages or charges sustained in the adaptation or use
of its engineering data and services. No representative of
Cla-Val may change any of the foregoing or assume any
additional liability or responsibility in connection with the
product. The liability of Cla-Val is limited to material
replacements F.O.B. Newport Beach, California.
Responsibly
We will not be responsible for delays resulting from strikes,
accidents, negligence of carriers, or other causes beyond our
control. Also, we will not be liable for any unauthorized
product alterations or changes accruing therefrom.
Risk
All goods are shipped at the risk of the purchaser, after
they have been delivered by use to the carrier. Claims for
error, shortages, etc., must be me upon receipt of goods.
Export Shipments
Export shipments are subject to an additional charge for
export packing.
Returned Goods
1. Customers must obtain written approval from Cla-Val
prior to returning any material.
2. Cla-Val reserves the right to refuse the return of any
products.
3. Products more than six (6) months old cannot be
returned for credit.
4. Specially produced, nonstandard models cannot be
returned for credit.
5. Rubber goods such as diaphragms, discs, O-rings,
etc., cannot be returned for credit, unless as part of an
unopened vacuum sealed repair kit which is less than
six months old.
6. Goods authorized for return are subject to a 35% ($75
minimum) restocking charge and a service charge for
inspection, reconditioning, replacement of rubber
parts, retesting, repainted and repackaging as
required.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 2
Table of Contents
1 Notes about this Documentation……………………………………………….
3
1.1 Validity of this Document………………….………………………………...….
3
1.2 Copyright………………...……………….……..………………………………..
3
1.3 Symbols………………….……………......………….…………...……………..
3
2Important Notes………………………………………..……….………………….
4
2.1 Legal Bases……………..……………………………….…………………...….
4
2.1.1 Subject to Changes………………...………………………….….………..
4
2.1.2 Personnel Qualifications………………………......……..….……………..
4
2.2 Safety Advice……………..……………………………………………..…...….
4
3Product Description……………..………………………………………….…….
6
3.1 Specifications……………..……………………………………………….....….
6
4Installation……………..……………….……………………………………….….
9
4.1 Unpacking……………..……..…………………………………………….....….
9
4.2 Mounting the Enclosure....……………………………………………….....….
9
4.3 Component Layout…...…..……………………………………………….....….
11
4.4 Wiring Connections……....……………………………………………….....….
12
4.5 Grounding & Shielding…...……………………………………………….....….
14
4.6 Cabinet Wiring………..…………………………..……………………….....….
16
5Software Setup and Operation…..….……………………………………….….
18
5.1 System Timers…………..……..………………………………………….....….
19
5.2 Normal Pump Start....…………………………………………………….....….
20
5.3 Pump Malfunction…...…..………….…………………………………….....….
20
5.4 Valve Malfunction…...…..…………..…………………………………….....….
21
5.5 Normal Stopping of Pump.……………………………………………….....….
21
5.6 Power Failure…...…..……………….…………………………………….....….
21
5.7 Alarms…...…..……………………………………………………………......….
22
6Modbus Communication……...…..….……………………………………….….
23
7Pump Control Applications…..…..….……………………………………….….
26
8Troubleshooting………………..…..….……………………………………….….
28

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 3
1 Notes about this Documentation
!!
Keep this documentation!
The operating instructions are part of the product and shall be kept for the entire lifetime of the device.
They shall be transferred to each subsequent owner or user of the device. Care must also be taken to
ensure that any supplement to these instructions are included, if applicable.
1.1 Validity of this Document
This documentation is only applicable to the device:
“Cla-Val PC-22D Electronic Pump Control Panel”.
The Cla-Val PC-22D shall only be installed and operated according to the instructions in this manual and
the system description.
1.2 Copyright
This Manual, including all figures and illustrations, is copyright-protected. Any further use of this Manual
by third parties that violate pertinent copyright provisions is prohibited. Reproduction, translation,
electronic and photo technical filing/archiving (e.g., photocopying) as well as any amendments require the
written consent of Cla-Val. Non-observance will involve the right to assert damage claims.
1.3 Symbols
Personal Injury!
Indicates a high-risk, imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Personal Injury Caused by Electric Current!
Indicates a high-risk, imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Personal Injury!
Indicates a moderate-risk, potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Note
!
!
DANGER
DANGER
WARNING

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 4
2 Important Notes
This section includes an overall summary of the most important safety requirements and notes that are
mentioned in each individual section. To protect your health and prevent damage to devices as well, it is
imperative to read and carefully follow the safety guidelines.
2.1 Legal Bases
2.1.1 Subject to Changes
Cla-Val reserves the right to provide for any alterations or modifications that serve to increase the
efficiency of technical progress. Cla-Val owns all rights arising from the granting of patents or from the
legal protection of utility patents. Third-party products are always mentioned without any reference to
patent rights. Thus, the existence of such rights cannot be excluded.
2.1.2 Personnel Qualifications
All sequences implemented on the Cla-Val PC-22D Valve Controller may only be carried out by electrical
specialist with sufficient knowledge in automation. The specialists must be familiar with the current norms
and guidelines for the devices and automated environments.
All changes to the controller should always be carried out by qualified personnel with sufficient skills in
PLC programming.
2.2 Safety Advice (Precautions)
For installing and operating purposes of the relevant device to your system the following safety
precautions shall be observed:
Do not work on components while energized!
All power sources to the device shall be switched off prior to performing any installation, repair or
maintenance work.
Installation only in appropriate housings, cabinets or in electrical operation
rooms!
The Cla-Val VC-22D Valve Controller are an open system. As such, install the system and its
components exclusively in appropriate housings, cabinets or in electrical operation rooms. Allow access
to such equipment and fixtures to authorized, qualified staff only by means of specific keys or tools.
DANGER
!
DANGER

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 5
Replace defective or damaged devices!
Replace defective or damaged controllers, since the long-term functionality of the device can no longer be
ensured.
Protect the components against materials having seeping and insulating
properties!
The components are not resistant to materials having seeping and insulating properties such as: aerosols,
silicones and triglycerides (found in some hand creams). If you cannot exclude that such materials will
appear in the component environment, then install the components in an enclosure being resistant to the
above-mentioned materials. Clean tools and materials are imperative for handling the controller.
Cleaning only with permitted materials!
Clean the Cla-Val VC22-D using oil-free compressed air or with ethyl alcohol and leather cloths. Do not
use any contact spray.
Do not reverse the polarity of connection lines!
Avoid reverse polarity of data and power supply lines, as this may damage the devices involved.
Avoid electrostatic discharge!
The controller is equipped with electronic components that may get destroy by electrostatic discharge
when you touch. Pay attention while handling the devices to good grounding of the environment (person,
job and packing).
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
!

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 6
3 Product Description
The Electronic Pump Control Panel shall provide control between the pump control valve and the pump,
to prevent surges in the system when the pump starts or stops. The control panel shall properly
sequence and control the pump start-up and pump shut-down procedure, providing both visual and
electronic status outputs for operating personnel. Panel shall protect the pumping system from damage
due to mechanical, hydraulic or power failure. Panel shall be pre-wired and include an integral
programmable valve controller to sequence the pump and pump control valve during all modes of
operation. Controller shall be pre-programmed for most common pump control applications. Controller
shall be easy to wire and adjust. Controller to include the following features:
•Sequence timers
•Local visual indication of pump and control valve status.
•Displays time for system to build pressure and for valve to open
•Contacts for remote or automatic start signal
•Local pump start & pump stop buttons
•Local emergency stop button
•Automatic shutdown of pump in emergency situations
•Terminal block connections for solenoid controls, valve limit switch, pump starter relay, remote
automatic contact, pressure switch
•HOA switch for remote or local operation
Custom application programming is available upon request. The control panel shall include automatic
recognition of common fault conditions and shall provide proper fault response sequencing to the pump
control valve and pump starter as well as visual and electronic fault notification to operating personnel.
The integral programmable valve controller shall be housed in a NEMA 4X fiberglass enclosure with
polycarbonate window, gasketed door, continuous stainless steel hinge, stainless steel twist/latch door
fasteners, and pad lockable door hasp.
ORDERING INFORMATION
Cla-Val Part
Number
Description
20977406F
PC-22D Electronic Pump Control Panel
Figure 1. PC-22D Electronic Pump Control Panel

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 7
3.1 Specifications
Material Specification for the Electronic Pump Control Panel as follows:
Panel Enclosure
Material Flame retardant UL rated PC/ABS plastic
Enclosure Panel Dimensions 20.0” (508 mm) H x 18.0” (457 mm) W x 9.0” (228 mm) D
The enclosure panel shall be provided with all necessary mounting
brackets.
Panel Integral Controller
Display Type 4.3” Color TFT-LCD, 480 x 272 pixels
Display Update Rate 100ms
Programming Method Mechanical Push Button VNC
Password 5 digit
Enclosure Environmental NEMA 4X
Controller Mass Data Storage
Type 4GB SD Card
Language English
Temperature Range 14°F to 158°F (-10°C to 70° C)
Humidity 90% RH, non-condensing
Memory Protection 10 year life lithium battery
Power Requirement
Power 120VAC @ 60Hz protected with 5 Amp Fuse & Circuit Breaker
Motor Starter Contacts: 10 amp maximum
Valve Solenoid Contacts: 10 amp maximum
Remote Alarm: 1 amp maximum
Controller Inputs
Analog 4-20mA; (6) Inputs Available (0-5 V / 0-10 V)
Resolution 10 bit
Digital (6) digital inputs (Dry contact)
Units Configurable
Decimal Point 0 / 0.0 / 0.00 / 0.000
Signal Filter Configurable 1 to 60 seconds
Totalizer Configurable Input and Units
Totalizer Reset Yes
I/O Connection Screw Terminals
Controller Outputs
Pump Relay 10 Amp Max
Control Valve Relays 120VAC @ 60Hz Output (double chamber valves)
24VDC Solid State Relay Output (single chamber valves)
Alarm Relay (2) Available and Configurable
Analog 4-20mA; (4) Outputs available
Resolution 10 bit
Solenoid (2) Solid State Relay, Zero Switching Voltage
Relay (2) Mechanical Relay, Rated Voltage 250VAC,
Rated Current 6A

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 8
Controller Input Logging
Configurable Yes
Logging Speed 1 minute
Event Memory 128 Mbytes rolling memory up to 80,000,000 values capacity
Output CSV format suitable for exporting to MS Excel
Controller Parameters
Control Input 4-20mA full scale / 0-5 V / 0-10V / digital (dry contact)
Proportional Band 0-100% (50% default) adjustable in 1% increments
Independently for opening and closing
Dead band Adjustable 0 to full scale of set-point signal
Cycle Time 0 to 60 seconds in 1 sec. increments
Integral Band Adjustable 0 to 60 seconds
Derivative Band Adjustable 0 to 60 seconds
Loop Zoning Adjustable up to (4) zones
PID Loops 4 Configurable
Control Curves 4
Retransmission 4 Analog (4-20mA signal)
Actions (Alarms) Triggering conditions
Controller Communication
Local Mechanical Push Button
Remote VNC Server
Interfaces GPRS Modem Quad Band / Ethernet / RJ-45 / RS-232 / RS-485
Protocols Modbus TCP / ModbusRTU / VNC
Conntroller Approvals
Conformity Marking CE marking
Controller Optional
Features /AccessoriesFan / Heater with integral thermostat

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 9
4 Installation
For Installation in USA: The Cla-Val VC-22D must be installed in accordance with the National
Electrical Code (NEC) NFPA 70.
For Installation in Canada: The Cla-Val VC-22D must be installed in accordance with the Canadian
Electrical Code CSA 22.1. All input circuits must be derived from a CSA approved Class 2 source.
For European Community: The Cla-Val VC-22D must be installed in accordance with the ATEX
directive 94/9/EC.
4.1 Unpacking
Remove enclosure from box. Inspect the packaging and contents for damage. Report damages, if any, to
the carrier.
If any part is missing or the control malfunctions, please contact your supplier or the factory for
assistance.
4.2 Mounting the Enclosure
The PC-22D Electronic Pump Control Panel is NEMA 4X rated. Molded fiberglass polyester with
enhanced UV inhibitors protect against outdoor weathering. Stainless steel mounting brackets and
hardware are provided for mounting to the rear of the enclosure.
1. PC-22D Enclosure Physical Dimensions:
Figure 2. PC-22D Enclosure Footprint Dimensions.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 10
2. PC-22D Enclosure Mounting Dimensions:
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
Figure 3. PC-22D Enclosure Mounting Dimensions.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 11
!
!
!
!
4.3 Component Layout
List of Components:
1. NEMA 4X Enclosure
2. Cla-Val VC-22D Controller
3. Power Supply 24VDC @ 40Watts
4. 5A Circuit Breaker
5. 5A Fuse Protection
6. (2) Mechanical Relays
7. Din Rail
8. Wiring Ducting
9. 3-Position Switch
10. Start Pump Switch –Green
11. Stop Pump Switch –Red
12. Emergency Stop Button
Figure 4. PC-22D Component Layout.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 12
4.4 Wiring Connections
Customer connections shall be made to the provided numbered terminal blocks located near the bottom
portion of the enclosure.
Stripped solid conductors, stranded conductors, or ultrasonically “bonded” conductors are easily
connected using a screwdriver.
Maximum Conductor Size: 12 AWG
1. System Supply
The PC-22D requires 110VAC @ 60Hz alternating current supplied to the enclosure. The product is
powered via terminal block 4 & 5 with CAGE CLAMP connections. The provided power supply generates
the necessary voltage to power the integral controller and valve solenoid/s.
Do not use an incorrect voltage/frequency!
The use of an incorrect supply voltage or frequency can cause severe damage to the product.!
NOTICE
Wire Removal
The conductor is removed using a
screwdriver.
Figure 5. Terminal Block
installation & removal.
!
110V
AC
The$110V$AC$supplies$power$to$
system$controller$and$valve$
solenoid.$
Figure 6. Supply Voltage Connections.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 13
2. Pump Start & Valve Solenoid Connections
The pump start signal shall be terminated on terminal block 10 & 11.This contact is pre-wired as a dry-
contact output. If the contact requires power, the maximum current is 10 amps.
The control valve solenoid shall be terminated on terminal block 12 & 13. This contact is pre-wired with
an output of 110VAC. Typically when wiring AC solenoids, polarity is irrelevant.
Terminals 6, 7, 8, & 9 are reserved for optional alarms. See the Software Programming section of this
manual for further explanation.
3. Remote Pump Start, Valve Pressure & Limit Switch Connections
Terminal block 14, 15, & 16 are reserved for a valve position transmitter or another type of 4-20mA
device. If using a standard pump control valves, these terminals will not be used.
The remote start signal from SCADA shall be terminated on terminal block 17 & 18. This contact is pre-
wired as a dry-contact input. When the contact is closed and the 3-position switch is set to remote, the
controller will interpret this as a pump run command.
The valve limit switch shall be terminated on terminal block 19 & 20. This contact is pre-wired as a dry-
contact input. When the contact is open, the controller will interpret as “valve open”. When the contact is
closed, the controller will interpret as “valve closed”.
110V
AC
Figure 7. Pump Start & Solenoid Terminals
!Alarms!
Activate in software menus!
Figure 8. Valve Limit Switch Connections.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 14
The pressure switch signal shall be terminated on terminal block 21 & 22. This contact is pre-wired as a
dry-contact input. When the contact is open, the controller will interpret as “minimum pressure not met”.
When the contact is closed, the controller will interpret as “minimum pressure met”.
If a pressure switch is not used!
If a pressure switch is not used, a jumper must be inserted across terminal block 21 & 22.
4.5 Grounding & Shielding Function
Grounding increases the resistance against disturbances from electromagnetic interferences. From the
field side, the ground wire shall be connected to any ground potential (green terminal block). The terminal
block is internally connect to the carrier rail.
NOTICE
Figure 9. Remote Start, Valve Limit Switch, & Pressure Switch Connections.
Figure 10. Grounding Connection Terminal Block.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 15
The use of shielded cables reduces electromagnetic interference and thus increases signal quality.
Measurement errors, data transmission errors and interference due to excessive voltage can be
prevented.
Shielded signal lines only required for analog signals connected to the Cla-Val Controller.
Connect the cable shield to the ground potential!
Integrated shielding is mandatory to meet the technical specifications in regards to measuring accuracy.
Connect the cable shield to the ground potential (green terminal block). This allows induced interference
to dissipate and to be kept away from devices in the cabinet.
Improve shielding performance by placing the shield over a large area!
Higher shielding performance is achieved via low-impedance connection between shield and ground. For
this purpose, connect the shield over a large surface area.
Keep data and signal lines away from sources of interference!
Route data and signal lines separately from all high voltage cables and other sources of high
electromagnetic emission (e.g. power supplies).
NOTE
NOTE
NOTE

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 16
4.6 Cabinet Wiring
Provided wiring diagrams are intended to be used as reference only.
Figure 11. Panel Wiring Diagram.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 17
Figure 12. Panel Wiring Diagram.

!
!
Cla-Val PC-22D Electronic Pump Control Panel
Installation, Operation & Maintenance Manual
Page | 18
5 Software Setup and Operation
The PC-22D Electronic Pump Control Panel powers on after switching the circuit breaker to the on
position. An indicator light illuminates on the power supply indicating power to controller and accessory
components. It takes approximately 40 seconds for the controller to complete its boot up procedure.
Once the controller has completed the boot up process, the home screen will appear with system
indicators and status.
1. Visual Indicators:
Indicator
Color Red
Color Green
Pump Status
Pump OFF
Pump ON
Pressure Switch
Pressure minimum not met
Pressure above minimum
Valve Open
Valve Closed
Valve Open
2. Status Indicators:
Time –Pressure = Time it takes for the pressure switch contact to close once the pump has been started.
This timer is displayed in seconds.
Time –Valve = Time it takes for valve to open once valve solenoid has been energized. This timer is
displayed in seconds.
Valve Solenoid = Displays whether the valve solenoid is energized or not.
Figure 13. PC-22D Controller Home Screen.