CLA-VAL 34 Series User manual

Cla-Val 34-Series
Installation, Operation, and Maintenance Manual
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34-Series
Electronic Actuated Pilot Control
Installation / Operation / Maintenance

Cla-Val 34-Series
Installation, Operation, and Maintenance Manual
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GENERAL DISCLAIMER
In accordance with our policy of continuous development and improvement, CLA-VAL reserves the right
to modify or improve its products at any time without prior notice. CLA-VAL assumes no liability or
responsibility for any errors or omissions in the content of this document.
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: [email protected]
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 34-Series
Installation, Operation, and Maintenance Manual
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Contents
1. Introduction...........................................................................................................................................5
2. Installation .............................................................................................................................................7
2.1 Unpacking ............................................................................................................................................7
2.2 Installation Instructions .......................................................................................................................7
2.3 Dimensions ..........................................................................................................................................7
3. Specifications.........................................................................................................................................8
3.1 Subassembly Specifications .................................................................................................................8
3.2 Electronic Specifications ......................................................................................................................9
4. Applications .........................................................................................................................................10
4.1 CRD-34 & CRA-34...............................................................................................................................10
4.1.1 CRD-34 VS CRA-34 ......................................................................................................................10
4.2 CRL-34................................................................................................................................................11
4.3 CDHS-34 .............................................................................................................................................12
4.4 Complementary Products............................................................................................................13
5. Electrical Wiring...................................................................................................................................14
5.1 34 Power/Signal Connections............................................................................................................14
5.2 Modbus Connections.........................................................................................................................15
5.3 Wiring Instructions ............................................................................................................................15
5.3.1 Wiring Example...........................................................................................................................15
6. 34 Series Calibration............................................................................................................................17
6.1 e-Drive Overview ...............................................................................................................................17
6.2 Static Calibration..........................................................................................................................18
6.2.1 Number Of psi Per Turn Calculation Example .....................................................................19
6.3 Dynamic Calibration...........................................................................................................................21
6.4 Extended Dynamic Calibration Mode: High Point Value.............................................................22
6.5 Configuration ...............................................................................................................................23
6.6 Alarms ..........................................................................................................................................24
6.6.1 Hysteresis.............................................................................................................................24
7. 34 Series Calibration Via VC-22D.........................................................................................................26
7.1 34 series to VC-22D Connection........................................................................................................26
7.2 Calibration Mode ...............................................................................................................................27
7.3 View Series 34 I/O in VC-22D.............................................................................................................28

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Installation, Operation, and Maintenance Manual
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8. Software Setup ....................................................................................................................................31
8.1 34 Series e-Drive Software ................................................................................................................31
8.2 USB Communication cable Driver......................................................................................................32
8.3 Firmware Download ..........................................................................................................................32
8.4 Firmware Update Procedure .............................................................................................................33
8.5 Configuration Mode...........................................................................................................................34
9. Modbus Interface ................................................................................................................................36
9.1 Standard Modbus Interface...............................................................................................................36
9.2 Register Table ..............................................................................................................................37
10. Troubleshooting 10.1 Troubleshooting Actuator Set-up ................................................................38
10.2 Troubleshooting FAQ.......................................................................................................................38
10.3 Notes................................................................................................................................................40

Cla-Val 34-Series
Installation, Operation, and Maintenance Manual
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1. Introduction
The 34 Series electronic actuated pilots offer accurate and reliable control of the valve. 34 Series
pilots are a 4-20 mA standalone actuated controller calibrated via PC through a maintenance
port and able to remotely control any Cla-Val valve. The pilot setting can be adjusted with a
standard 4-20 mA signal, and 4-20 mA position feedback is available to cross check if requested
position is reached.
34 series pilots include:
•CRD-34 & CRA-34 “Electronic Actuated Pressure reducing pilot control”.
•CRL-34 “Electronic Actuated Pressure sustaining pilot control”.
•CDHS-34 “Electronic Actuated rate of flow pilot control”.
The 34 series includes the following features:
•Ideal for Pressure/Flow optimization
•Simplified Remote Valve Set-point Control
•Modbus RTU Communication
•Easy integration with VC-22D Electronic valve controller
•12 to 24 VDC Input Power
•Isolated input
•Reverse Polarity protection
•IP-68 Submersible
•Calibrated Via PC and VC-22D
Figure 1: 34-series overview.

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Installation, Operation, and Maintenance Manual
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Cla-Val Electronic Actuated Pilot Controls are a simple and effective solution to add or improve
electronic control in waterworks valve applications. They allow for remote valve set point control,
are ideal for use with SCADA systems and can be adjusted to accommodate changing
requirements. The 34 Series Pilot Control can be easily retrofitted to an existing valve in the field
without removal from the pipeline.
Typical applications include the following major control functions.
•Pressure Reducing
•Pressure Management
•Pressure Sustaining
•Rate-of-Flow Control
•Reservoir Filling
•Combination Pressure Reducing/Pressure Sustaining

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Installation, Operation, and Maintenance Manual
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2. Installation
2.1 Unpacking
Remove Pilot 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.
2.2 Installation Instructions
Recommended installation for the 34 series is vertical with
the valve to ensure proper operation.
•All installation, adjustment and maintenance should
be carried out by a competent electrician.
•Do not exceed the maximum ratings given in the
specifications and printed on the label.
•The electrical connections should be made as
described in the user’s manual.
•Before any maintenance operation the main power
should be turned off.
Figure 2: Recommended installation of 34 series
2.3 Dimensions
The following dimensions are the same for all 34 series pilots:
Figure 3: 34 series electronic actuated pilot dimensions.

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Installation, Operation, and Maintenance Manual
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3. Specifications
3.1 Subassembly Specifications
Specification
CRD-34 & CRA-34
CRL-34
CDHS-34
Adjustment
Ranges
2 - 30 psi (3 psi per turn)
15 - 75 psi (9 psi per turn)
40 - 140 psi (27.5 psi per turn)
7 –75 psi (8.5 psi per turn)
20 –105 psi (13 psi per turn)
20 –200 psi (28 psi per turn)
70 –480 inches
H2O Differential
End
Connection
3/8” NPT
½” and 3/4” Threaded
3/8” NPT
Temperature
Range
Water: to 176 F / 80 C
Water: to 176 F / 80 C
Water: to 176 F / 80 C
Materials
Pilot Control: Low Lead Bronze
Trim: Stainless steel Type 303
Rubber: Buna-N synthetic
rubber.
Available with optional
Stainless Steel or Monel
materials at additional cost.
Consult factory for details.
Note: Available with remote
sensing control (specify Model
# CRA-34)
Pilot Control: Low Lead
Bronze
Trim: Stainless steel Type 303
Rubber: Buna-N synthetic
rubber.
Available with optional
Stainless Steel or Monel
materials at additional cost.
Pilot Control: Bronze
ASTM B62
Trim: Stainless steel Type
303
Rubber: Buna-N synthetic
rubber.
Available with optional
Stainless Steel or Monel
materials at additional
cost. Consult factory for
details Note: Available
with Remote Sensing for
orifice upstream, specify
CDHS-34A
Weight
8 Lbs.
8 Lbs.
8 Lbs.
Environmental
Protection
IP68, Validated 1 month at 0.2
bar/2.9 psi
IP68, Validated 1 month at
0.2 bar/2.9 psi
IP68, Validated 1 month
at 0.2 bar/2.9 psi

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Installation, Operation, and Maintenance Manual
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3.2 Electronic Specifications
Specification
CRD-34 & CRA-34 / CRL-34 / CDHS-34
Electrical Power:
•10 VDC to 30 VDC
•16 rpm nominal speed @ 24 VDC
•8 rpm nominal speed @ 12 VDC
500 mA max. (actuating mode) @ 16 bar ~ 232 Psi
800 mA max. (actuating mode) @ 21 bar ~ 304 Psi
350 mA average nominal
30 mA stand-by (un-actuating mode)
CLA-VAL recommended power supply is the e-Power-IP turbine for a
completely autonomous system
Power Protection:
Max. 32 VDC overvoltage
Max. 1 A couple limitation
Polarity inversion & short circuit
Automatic shut-down at 80°C internal
Operating diagnostic:
Through diagnostic LED as referenced in the user manual (Green / Red /
Blinking)
Electrical connection:
1x 30 ft shielded cable (12 wire)
Wire section: 0.22 mm2
Cable diameter: 6.9 mm
1x 6-pin Serial connector for Modbus communication
1x3-pin connector for computer connection / maintenance
Control inputs:
•4-20 mA (2 wires)
•2x dry contact (manual operation)
•Modbus RTU 485 Serial 6-pin connector
4-20 mA input protection:
Max. 32 VDC over voltage
Insolation (2 wires)
Optocoupler isolation CMR 1000 V
(CMR: common mode rejection)
Position feedback:
•4-20 mA (load impedance ≤ 500 Ω)
•2x programmable alarm position 10-32 VDC / 110-240 VAC at max
1 A
4-20 mA output protection:
Max. 32 VDC over voltage (dry contact input and 4-20 mA output at the
same voltage, un isolated to each other)

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Installation, Operation, and Maintenance Manual
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4. Applications
4.1 CRD-34 & CRA-34
The CRD-34 and CRA-34 are installed on the Cla-Val 390 Series valves that maintain downstream
pressure and require this pressure to be changed from a local/remote location. It can be an
effective solution for lowering costs associated with "confined space" requirements by
eliminating the need for entry in valve structure for set-point adjustment. It is also ideal for
pressure management and can be programmed to minimum nighttime and optimum daytime
pressures. Remote set-point command signals can be from any SCADA-type control system using
an analog 4-20 mA signal, by contact closure for CC/CCW rotation, or through Modbus RTU.
Figure 4: Typical Installation of CRD-34 & CRA-34
4.1.1 CRD-34 VS CRA-34
The CRD-34 senses valve outlet pressure directly and the CRA-34 senses downstream pressure
with remote hydraulic connection. Existing manually set Cla-Val 90 Series Pressure Reducing
control valves can be retrofitted with CRD-34 or CRA-34 to add remote set-point control of
delivery pressure.
The CRD-34 and CRA-34 consists of a hydraulic pilot and integral controller that accepts a
remote set-point and positions the pilot to maintain a pressure at valve outlet within preset
limits. Pressure settings are linear between these settings. Pressure settings are calibrated to
the specific spring range of the control. Continuous internal monitoring of actuator position
results in smooth transitions between pilot set-points with no backlash or dithering. Should
power or control input fail, this pilot remains in automatic hydraulic control assuring system
stability under all conditions.

Cla-Val 34-Series
Installation, Operation, and Maintenance Manual
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4.2 CRL-34
The CRL-34 is installed on Cla-Val 350 Series valves to maintain constant upstream pressure
within close limits and allows this pressure to be changed from a remote location. This pilot can
be an effective solution for lowering costs associated with "confined space" requirements by
eliminating the need for entry in valve structure for set-point adjustment.
The Model CRL-34 Electronic Actuated Pressure Sustaining Pilot Control provides remote set-
point adjustment and accurate upstream pressure control. Remote set-point command signals
can be sent from Cla-Val’s VC-22D e-Controller or any SCADA-type control system using an
analog 4-20 mA signal, by contact closure for CC / CCW rotation, or through Modbus RTU.
Figure 5: Typical Installation of CRL-34.
Existing manually set Cla-Val 50 Series Pressure Relief / Pressure Sustaining Control valves can
be retrofitted with CRL-34 pilots to add remote set-point control of upstream pressure.
The CRL-34 consists of a hydraulic pilot and integral controller that accepts a remote set-point
and positions the pilot system to sustain a pressure at the valve inlet within preset limits.
Pressure settings are linear between these settings. Pressure settings are calibrated to the
specific spring range of the pilot control.

Cla-Val 34-Series
Installation, Operation, and Maintenance Manual
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4.3 CDHS-34
The Cla-Val Model CDHS-34 Electronic Actuated Differential Pressure Pilot Control provides
remote set-point adjustment and accurate differential pressure control for rate of flow control
on Cla-Val 340 Series Control Valves.
Remote set-point command signals can be from any SCADA-type control system using analog 4-
20 mA signal, by contact closure for CC/CCW rotation, or through Modbus RTU.
Figure 6: Typical Installation of CDHS-34.
A precision orifice plate installed with valve creates differential pressure used for rate of flow
control by the CDHS-34.
Existing manually set Cla-Val 40 Series Rate-of-Flow control valves can be retrofitted with CDHS-
34 to add remote set-point control.
The CDHS-34 consists of a hydraulic pilot and integral controller that accepts a 4-20 mA remote
set-point and positions the pilot to maintain a maximum pressure differential at orifice plate and
corresponding flow rate within preset limits.
The CDHS-34 Is installed on Cla-Val 340 Series valves to maintain flow rate and allow the flow
rate to be changed from a remote location. Additional pilot controls, hydraulic and/or
electronic, are also available to perform multiple functions to fit exact system requirements.

Cla-Val 34-Series
Installation, Operation, and Maintenance Manual
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4.4 Complementary Products
The 34 Series motorized pilot can comply with many Cla-Val Products such as:
1. VC-22D Valve Controller: Vc-22D controller as a very powerful tool which can control many
devices in addition to 34 series with multiple communication protocols.
2. X143IP Power Generator: the X143IP can power the 34, power calculations may be required.
3. X144D e-Flowmeter: The X144D is an additional complementary product that can also be
used along with the 34-series.
4. X145 Electronic Display: having an electronic display with the 34-series can be very helpful.
5. XF2F package: Cla-Val new XP2F package is another source of flow metering which can also
be complementary with the 34 series.
Figure 7: Complementary Products With 34 Series.

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Installation, Operation, and Maintenance Manual
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5. Electrical Wiring
5.1 34 Power/Signal Connections
The 34 series comes with a 12-wire shielded 30 ft cable and its configured wiring as follows:

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Installation, Operation, and Maintenance Manual
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5.2 Modbus Connections
The connection side of the 34 series is circular plug type, And the connection side of the VC-22D
is a screw terminal. The connection of the VC-D22 side must be wired as the following table:
5.3 Wiring Instructions
Before running actuator or software program, complete the following hookup steps:
•Avoid potential ground loops.
•Avoid over tightening wiring connector fasteners.
•The enclosure is rated IP-68 submersible for short periods of time. It is not intended for
continuous underwater use.
•Consult Cla-Val factory technical support if you have questions.
•The twelve - wire 30 ft cable is attached to 34 Series actuator and should be terminated
in suitable junction box or directly into an above grade RTU or similar device.
•Care should be used when attaching to wires to avoid damage.
•Installation of suitable protection from lightning is highly recommended.
•There are no user serviceable parts inside the actuator and tampering or opening it will
void the warranty.
•The twelve-wire actuator cable is permanently attached. Internal damage not covered
by warranty will occur if cable is removed.
5.3.1 Wiring Example
Terminate wires only applicable to your application. For example, minimal wiring
requirements for power and remote set point are as follows:
1. Attach 12 to 24 VDC power to 34 Series Actuator cable. Black wire is for (-) negative;
Red wire is for (+) positive. Provide minimum 500 mA supply.
2. Attach 4 to 20 mA analog Remote Command Input (from SCADA system or loop
calibrator) to 34 Series Actuator cable. Yellow is positive and Grey is negative.
3. After wiring is complete and actuator is powered, it can be used with 4 - 20 mA
remote command input signal scaled to factory default pilot control adjustment
range (Operation A, above).

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Installation, Operation, and Maintenance Manual
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Installation, Operation, and Maintenance Manual
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6. 34 Series Calibration
Before beginning the calibration process, determine if it is necessary! The actuator, if new, has
been factory calibrated to the spring range shown on the pilot and may not require further
calibration (30-300 spring range is calibrated from 40 to 140 psi).
Hardware set-up steps must be completed before program will communicate. Until wiring and
power connections are made to the actuator, the software program can be opened, but new
parameters cannot be created or stored or sent to actuator.
Configure the e-drive as follows:
6.1 e-Drive Overview
Connect laptop computer to actuator using special multi-USB cable. Be sure computer is on and
actuator is powered. Check that Actuator LED is steady green, and perform the steps below:
1. Start the e-Drive / CLA-VAL
software.
2. Select the e-Drive in the e-Line
list.
3. Select language and click "Read
parameters".
4. The right side will display specific
configuration information.
5. General information including:
a. the date of latest calibration.
b. the average & total working time since the first power up.
c. the number of starts.
d. the serial number.
e. the firmware version.
f. the maximum and minimum recorded temperature is displayed.
6. Click on continuous reading to see the position of e-Drive, set point (mA) and, if used
feedback position (mA and units).
7. To manually change the setting, write the setting and click on "Override Set point".
CAUTION: Improper use of "Override Set point" may cause damage to your system.
Figure 8: e-Drive Name Specifications.

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Figure 9: e-Drive Screen Layout.
6.2 Static Calibration
Static Calibration is a fast and convenient method of calibrating the actuator by calculating
the 4 and 20 mA values rather than raise or lower the actual system pressure. Dynamic
Calibration requires that the system pressure is raised and lowered to the system values
desired.
The “Set Range” window will launch either Static or Dynamic calibration. When the "Set
Range" is activated, the following message will be displayed. To continue with calibration,
click "OK”, if not click "Cancel".
Figure 10: Confirmation Screen.
1. Select "Static Calibration" Mode. Uncheck The "CPC Motor".
2. Use increase and decrease buttons to modulate valve to maintain setpoint used most.
3. Calculate the number of turns between the reference set point and desired low and high
pressures per section 6.2.1
4. These numbers are the "Value at 4 mA" and the Value at 20 mA". Numbers must be
positive and can have up to 2 decimal places.

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5. Enter the low value in set-point window (1).
6. Enter the high value in set-point window (2).
7. Click "Write Set Range" tab to complete actuator to complete calibration.
Figure 11: Static Calibration Screen.
6.2.1 Number Of psi Per Turn Calculation Example
Example Program:
•Current pressure = 22 Psi
•The pressure desired at 4 mA is 15 Psi.
•The pressure desired at 20 mA is 30 Psi.
•Spring range for the 34 series is 15-30 Psi.
•The number of turns to Low set point is equal:
Pressure difference = 22 psi –15 psi = 7 Psi.
7 psi * (1 Turn / 10 Psi) = 0.7 Turns.
The number of turns to High set point is equal:
Pressure Difference = 30 Psi –22 Psi = 8 Psi
8 Psi * (1 Turn/10 Psi) = 0.8 Turns.
See figure 13 for low point-high point adjustment.

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After calculating low point and high point based on the spring range of the 34 series actuator and having
a static calibration, values should be entered in the software accordingly low point and high point and
write set range as shown in figure below.
Figure 12: low point high point settings.