CleaverBrooks PCS140e.1 User manual

750-329
05/2010
Packaged Water Systems
Pump Sequence
& Pressure Control
Model PCS140e.1
Installation, Operation, and Parts

TO: Owners, Operators and/or Maintenance Personnel
This operating manual presents information that will help to properly operate and care for the equipment. Study its con-
tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc-
tions are followed. No attempt should be made to operate the unit until the principles of operation and all of the
components are thoroughly understood.
It is the responsibility of the owner to train and advise not only his or her personnel, but any contractor’s personnel who
are servicing, repairing, or operating the equipment, in all safety aspects.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical
and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however,
proper operating techniques and maintenance procedures must be followed at all times.
Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely
free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.
It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instruc-
tions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of
the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before
attempting to operate, maintain, service, or repair this equipment.
Operating controls will normally function for long periods of time and we have found that some operators become lax in
their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and
deficiencies in testing and maintenance.
The operation of this equipment by the owner and operating personnel must comply with all requirements or regulations
of the insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between
such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

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CLEAVER-BROOKS Pump Sequence and Pressure Control System
Model PCS140e.1
Installation, Operation, Service and Parts Manual
Manual Part No. 750-329

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Table of Contents
CHAPTER 1 GENERAL DESCRIPTION AND PRINCIPLE OF OPERATION ........................... 5
1.1 Introduction..................................................................................................................5
1.2 How to Use this Instruction Manual ................................................................................5
1.3 System Description - General..........................................................................................5
1.4 Principle of Operation ....................................................................................................5
1.5 System Components......................................................................................................5
1.6 Standard Warranty ........................................................................................................6
CHAPTER 2 INSTALLATION ............................................................................... 7
2.1 System Requirements ....................................................................................................7
2.2 Determining Locations ...................................................................................................7
2.4 Wiring .........................................................................................................................7
CHAPTER 3 SYSTEM SET-UP AND CONFIGURATION ................................................. 9
3.1 PLC Overview ...............................................................................................................9
3.2 Data Logging ................................................................................................................9
3.3 Remote Monitoring........................................................................................................9
3.4 HMI Screens.................................................................................................................9
Main Menu Screen.........................................................................................10
Overview Screen............................................................................................10
Overview Trend Screen...................................................................................11
System Setup Menu Screen.............................................................................11
Analog Input Scaling Screen............................................................................12
Digital I/O Screens .........................................................................................12
System Options Screen...................................................................................13
Setpoint Entry Screens ...................................................................................13
Pump Sequence Screen..................................................................................14
Pump Elapsed Hours Screen ...........................................................................14
Data Logging Screen ......................................................................................15
Password Entry Screen...................................................................................15
Alarm Summary and History Screens ...............................................................16
3.5 Control Panel..............................................................................................................16
HMI Display .................................................................................................16
Power Supply................................................................................................16
Relays..........................................................................................................16
Circuit Breaker/Fuse Blocks ............................................................................16
CHAPTER 4 PLACING SYSTEM INTO OPERATION ................................................... 17
4.1 Supplying Power to the System.....................................................................................17
4.2 System Setup and Configuration ...................................................................................17

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CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING ............................................ 19
CHAPTER 6 PARTS ....................................................................................... 21
APPENDIX A - I/O LISTING .......................................................................... 22
APPENDIX B – REMOVABLE MEDIA............................................................. 23
APPENDIX C – MODBUS SLAVE ADDRESSING ............................................. 24

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CHAPTER 1 - GENERAL DESCRIPTION AND PRINCIPLE OF OPERATION
1.1-Introduction
Congratulations and thank you for choosing the Cleaver-Brooks PCS140e.1 pump control system. This
system has been designed with the user in mind, and should provide many years of dependable, safe,
and efficient operation. To ensure continued trouble-free operation, please be sure to follow all
instructions in this manual regarding proper installation, set-up, operation, and maintenance.
1.2-How to Use this Instruction Manual
This manual is arranged to provide a straight forward, step-by-step process from installation through
operation and maintenance of your system.
Chapter 1 describes the system, components, and principles of operation, and explains how to identify
what type of system and components you should have.
Chapter 2 details the installation procedures, including mounting, wiring, and utility requirements, and
the proper sequence to perform these procedures.
Chapter 3 explains how to setup the system and place it into operation.
Chapter 4 provides information on routine maintenance, troubleshooting, replacement parts, and
warranty policy.
The appendix includes other pertinent information such as I/O addressing and information for remote
data monitors.
1.3-System Description - General
The C-B PCS140e.1 System is a PLC based control system designed to maintain water pressure in a
common header using a 4-20 mA pressure signal to control up to four (4) pump starters.
The PCS140e.1 uses a 3.5” 160x128 monochrome LCD touchscreen display. The complete system
comprises a pressure sensor and a control panel which houses the PLC. This system is connected to
a motor control center and the LWCO switch on the source water tank.
The system provides visual indication of header pressure, pump sequence, run status and alarms.
1.4-Principle of Operation
The system monitors the pressure in the common feedwater header and acts to maintain the desired
pressure by adding or shedding pumps as required. When the header pressure drops below the low
pressure setpoint for a period of time, an additional pump is started. When the header pressure
exceeds the high pressure setpoint for a period of time, a pump is shut off. The pumps are controlled
with a sequenced Lead-Lag basis in either a First On-First Off or a Last On-First Off mode (user
selectable). In Last On-First Off mode, the pumps may be automatically rotated on a timed basis. The
operator may also select the Lead-Lag sequence for the pumps.
Manual controls are provided to bypass the PLC for maintenance or troubleshooting purposes. The
system monitors the LWCO contact in the source water tank. All pumps are stopped on a low water
condition.
1.5-System Components
• Pressure Sensor - a pressure sensor is installed in the water header to provide a 4-20 mA signal
to the control system.
•PLC/HMI - The system is controlled by an integrated HMI / Programmable Logic Controller
(PLC). I/O modules allow the PLC to interface with all the field equipment (motor starters, LWCO
and pressure sensor). The PLC may communicate via Modbus RTU protocol to building
management or SCADA systems provided by others.

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1.6-Standard Warranty
The standard warranty on all Cleaver-Brooks Products is as set forth in form C9-188L4, Terms and
Conditions of Sale

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CHAPTER 2 - INSTALLATION
2.1-System Requirements
Electrical
120 VAC, 60 Hz, or 110 VAC 50 Hz 10 Amp
3-wire grounded system.
Environmental
Temperature:
Control Panel 32-122 °F
2.2-Determining Locations
General instructions for determining equipment mounting locations:
The interconnecting signal cables between the PCS Panel and field devices should be located as far as
possible from high voltage wiring and large electrical equipment. Devices such as the pump motor can
introduce voltage spikes which could upset the operation of the PLC. The signal cables should be run
at right angles to any power wiring and must not be routed with any boiler wiring.
The Control Panel may be mounted on a pedestal, a wall, or a convenient post. It should be located
away from large or high voltage equipment such as power distribution panels, motors, ignition
transformers, etc. If pedestal mounted, the base must be securely anchored.
2.3-Wiring
The control panel requires 120 VAC at 10 Amp. All wiring must conform to the National Electrical
Code (NEC), and all applicable local codes.

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