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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CHAPTER 3 - SYSTEM SET-UP AND CONFIGURATION
3.1-PLC Overview
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. In
the event of a low water condition in the source tank, the LWCO input is lost and all pumps are
stopped. A set of dry contacts is available for remote alarm indication
3.2-Data Logging
The PLC can log data to an optional micro SD memory card. When Data Logging is enabled, data for
the water level setpoint, actual water pressure, pump on/off status, pump lead-lag sequence, and I/
O status are written to a CSV file on the memory card. A new data log file is created every hour with
a time and date coded file name: MMDDHH.CSV. Data logging can be enabled/disabled and the
logging interval set at the HMI. The used capacity of the memory card is also displayed at the HMI.
To install a micro SD card: Align its 8-pin gold edge connector down, facing the ront of the HMI.
Carefully push it all the way into the memory slot. Ensure that it clicks into place.
To remove the micro SD card: Disable data logging before removing. Push down on the top of the card
gently to release the spring. The card will pop up for removal.
3.3-Remote Monitoring
The PlC provides data via Modbus RTU serial protocol. See Appendix C for address information and
communications parameters.
3.4-HMI Screens
The HMI displays all the information related to the PCS140e.1 system. There are several screens that
are used to view and/or change the system parameters.

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Main Menu Screen
This screen is the primary navigation screen to gain access to all the other screens. The ‘F1’ button is
used to access the Pump Elapsed Hours screen. The ‘F2’ button is used to access the System Setup
Menu screen. The ‘F3’ button is used to access the Alarm History screen. The ‘F4’ button is used to
access the Alarm Summary screen.
Overview Screen
This screen displays all the pertinent data for the system, including header pressure, pump sequence
and run status. The current elapsed run time is also displayed. When using Last On-First Off mode,
the time setpoint for automatic rotation may be adjusted.

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Overview Trend Screen
This screen displays the tank level information in a trend format. The level are also displayed in
numerical format.
System Setup Menu Screen
This screen allows the operator to access the setpoint and configuration screens. This screen is
password protected.

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Analog Input Scaling Screen
The screen allows the operator to adjust the raw input and scaled values for each analog input point.
Normal signal values are 4 and 20 mA. The scaled values should correspond to the engineering unit
range of the level transmitter that is wired to the analog input.
Digital I/O Screens
The DI Status screen allows the operator to view the status for each digital input point. When an input
signal is on, the corresponding indicator for that point is highlighted. When the input signal is off, the
indicator is clear.
On the DO Status screen operator can view the current status of the output points, and is able to ‘force’
each output to an ON state by pressing the button corresponding to the digital output point.
Note: When the DO Status screen is displayed, the normal control values for the digital output points
may be overridden by operator input. Changes should not be made while the system is in operation.

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System Options Screen
This screen is used to set the site-specific configuration of the system. The number of pumps to be
used is entered. The unit of measure for the pressure transmitter is selected. The operator can also
configure the ModbusThis data communications parameters and clear the Alarm history. This screen
is also used to access the ‘System’ area of the PLC controller to set the time/date.
Setpoint Entry Sceens
These screens allows the operator to adjust the pressure setpoints for adding or shedding a pump.
The operator can also set a time delay between pump starts/stops to avoid cycling pumps on a
momentary excursion outside of the normal operating range and to give the system time to react to the
effects caused by newly started or shed pumps.

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Pump Sequence Screen
This screen displays the current sequence and total run hours for each pump. The user can use this
screen to change the rotation order of the pumps.
Pump Elapsed Hours Screen
This screen shows the total elapsed run hours for each pump. The user can use this screen to reset
the run hours for each of the pumps.

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Data Logging Screen
The screen is for controlling the removable media (Micro SD card). The operator can enable or disable
data logging and the memory card. The data logging needs to be disabled before removing the memory
card. The data logging time interval can be adjusted on this screen as well. The time range is from 1
second to 3600 seconds (once per hour). The data logging status and disk usage are displayed. The
operator can also backup and restore the PLC data registers.
Password Entry Screen
The screen is for entering passwords to access secured screens.

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Alarm Summary and History Screens
The screen displays the current alarms for the system. Each alarm is time stamped. The operator may
also acknowledge alarms at this screen. The ‘F4’ button is used to access the alarm history screen.
This screen displays a historical record of all alarms and the time they were acknowledged.
3.5-Control Panel
(1) HMI Display – The PLC has a built-in display screen. It shows all the information pertaining to the
LCS system and is the means for operator interface to the PLC. All operating parameters are entered
and/or adjusted via this interface.
(2) Power Supply – The 24 VDC power supply mounted on the back panel provides power to the PLC/
HMI.
(3) Relays – The relays provide dry contacts for use by the customer as well as an interface with the
pump motor starters.
(4) Circuit Breaker/Fuse Blocks – These provide protection from electrical shorts caused by improper
wiring or damaged electrical equipment.

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CHAPTER 4 - PLACING SYSTEM INTO OPERATION
It is suggested the following sequence be used when the PCS140e.1 is started for the first time. If, at
any time, the expected result is not obtained, see the troubleshooting chapter. Before applying power
to the unit inspect all wiring
4.1-Supplying Power to the System
Check that the supplied voltage is 120 VAC (+/- 10%). Turn all of the pump Hand-Off-Auto switches
to the ‘Off’ position. Turn on the main power breaker. The PLC will power up and the HMI will display
the Main Menu screen. Verify that there is adequate water level in the source tank (above LWCO level).
4.2-System Setup and Configuration
The system needs to be configured to reflect the various options that are required the specific
installation.
Setting System Options
1.From the main menu screen, access the Setup Screen Menu by pressing the ‘F2’ button.
2.After entering the correct password, select “System Options”
3.Enter the correct password for access to the System Option screen.
4.Enter the correct number of pumps (2, 3 or 4) for the system.
5.Enter the correct units for the header pressure (psi, kPa, or bar).
6.If Modbus data monitoring is desired, turn the Modbus port on by pressing the button. The Modbus address has
a default value of 1. A different value may be entered at this screen.
7.Press ‘F1’ to return to the System Setup menu.
I/O Configuration/verification
1.Select “I/O Config” from the System Setup menu.
2.At the I/O Config menu, select the “Analog In Config” button.
3.Enter appropriate parameters for the header pressure transmitter. Typically, the ‘Raw’ signal values will be 4 and
20 mA. The Scale values should correspond to the range of the transmitter in the selected units of measure-
ment (psi, kPa or bar). The actual values for the input signal and the scaled signal are displayed.
4.Press ‘F1’ to return to the I/O Config menu.
5.Select the ‘Digital I/O’ button.
6.Turn each H-O-A switch to the ‘Auto’ position and verify that the correct inputs are highlighted.
7.Return each switch to the ‘Off’ position and verify that the inputs return to a non-highlighted state.
8.Turn each H-O-A switch to the ‘Hand’ position and then back to the ‘Off’ position. Verify that each pump starter
pulls in and the correct pump runs. Verify that the correct ‘Pump Running’ input is highlighted while the pump
is on and returns to the non-highlighted state when the pump is off.
9.Press the ‘Dig Outs’ button to access the Digital Output screen.
10.With the H-O-A switches off, press each of the DO buttons and verify that the correct relay changes state while
the button is pressed. Relays that are off will turn on and relays that are on will turn off when the button is
pushed.
11.For each pump, turn the H-O-A switch to the ‘Auto’ position and press the corresponding DO button. Verify
that the correct pump runs. Repeat for all pumps.
12.Press ‘F1’ until the System Setup Menu is displayed.
Setpoint Entry
1.Select the ‘Setpoint Config’ button.
2.Enter the Low Pressure setpoint. When the header pressure falls below this level, another pump will be started.

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3.Enter the Low Pressure time delay. This is the amount of time (in seconds) that the system will wait before
starting additional pumps on a low pressure condition.
4.Repeat for the High Pressure setpoint. When the header pressure rises above this level for the amount of time
defined with the delay setpoint, a pump will be turned off. A minimum of one pump will be run at all times.
5.Choose ‘First On-First Off’ or ‘Last On-First Off’ for the rotation mode. In ‘First On-First Off’ mode, the lead
pump is rotated to the last position in the sequence whenever a pump is turned off on a high pressure condi-
tion. The remaining pumps move up in the sequence. In ‘Last On-First Off’ mode, the last pump started will be
the pump that is turned off on a high pressure condition.
6.After all pressure setpoints have been set, press the ‘Alarm Setpoints’ button to enter the alarm setpoints.
Alarm Setpoint Entry
1.Enter the header pressure values at which the system triggers an alarm condition. A time delay for each may
also be set to avoid nuisance alarms caused by momentary spikes or excursions past the alarm setpoints.
2.Press the ‘F1’ button to return to the Main menu.
Acknowledge alarms
1.From the Main Menu screen, press the ‘F4’ button.
2.If any alarms are indicated on the Alarm Summary screen, they may be acknowledged by touching the alarm
summary and pressing the ‘Ack’ or ‘Ack All’ button.
3.Press the ‘F1’ button to return to the Main menu.
Pump Sequence Entry
1.From the Main menu, press the ‘Seq’ button to access the pump sequence screen. The current Lead-Lag
sequence of the pumps is shown as well as the total elapsed run hours for each pump.
2.The sequence may be changed by touching the pump position and using the up/down arrows to select the
desired pump for that position. Each pump may only be assigned to one position, and all pumps must be
assigned to a position. If an invalid sequence is entered, the changes will not be saved and the operator will be
alerted that the entered sequence is invalid.
3.When a valid sequence is entered, press the ‘Save’ button. The sequence will immediately go into effect. Press-
ing the ‘Cancel’ button leaves the screen with no changes to the sequence.
Rotation Time Set
If Last On-First Off mode is set, the operator may set an automatic rotation time by touching the
‘Rotation Hours’ button and entering a value. When the elapsed run time of the lead pump is greater
than the time setpoint, it is shifted to the last lag position and the other pumps move up in position.
If this time is set to zero, automatic timed rotation is disabled. The pumps will then only rotate in the
event of a pump failure, or by manually changing the sequence order.
Pumps to Auto
When the above steps are finished, initial setup is complete. Turn the HOA switches for the pumps to
the Auto position for normal operation.