CLA-VAL PC-22D Installation, Operation & Maintenance 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.

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Cla-Val PC-22D Electronic Pump Control Panel

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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.

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Table of Contents

1 Notes about this Documentation……………………………………………….

3

1.1 Validity of this Document………………….………………………………...….

3

1.2 Copyright………………...……………….……..………………………………..

3

1.3 Symbols………………….……………......………….…………...……………..

3

2 Important 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

3 Product Description……………..………………………………………….…….

6

3.1 Specifications……………..……………………………………………….....….

6

4 Installation……………..……………….……………………………………….….

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

5 Software 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

6 Modbus Communication……...…..….……………………………………….….

23

7 Pump Control Applications…..…..….……………………………………….….

26

8 Troubleshooting………………..…..….……………………………………….….

28

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1 Notes about this Documentation

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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

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DANGER

DANGER

WARNING

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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

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DANGER

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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

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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

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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

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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 /Accessories Fan / Heater with integral thermostat

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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.

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2. PC-22D Enclosure Mounting Dimensions:

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Figure 3. PC-22D Enclosure Mounting Dimensions.

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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.

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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$supplies$p o wer$to$
system$controller$and$valve$
solenoid.$

Figure 6. Supply Voltage Connections.

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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 dry­contact 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 pre­wired 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 dry­contact 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.

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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.

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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

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4.6 Cabinet Wiring

Provided wiring diagrams are intended to be used as reference only.

Figure 11. Panel Wiring Diagram.

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Figure 12. Panel Wiring Diagram.

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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.

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5.1 System Timers

The PC-22D Electronic Pump Control Panel is equipped with (2) timers; the time allowed for pressure to
build once the pump has been turned on and the time allowed for the valve to open. Both timers have a
default value of 30 seconds.

The system timers are access using the 5 button keypad on the controller.

From the home screen, click the down arrow to access the timer menu.

To toggle between timers, use the buttons on the keypad.

Timers are selected using the button. The text box will highlight red and the value
can be changed.

Figure 14. PC-22D Controller Timer Menu.

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5.2 Normal Pump Start (Local or Remote)

A local pump start command shall be initiated by turning the 3-position selector switch to the “local”
position and pressing the pump start green button. A remote pump start command shall be initiated by
turning the 3-position selector switch to the “remote” position and sending a remote start command to the
enclosure.

The pump shall immediately turn on and shall be seen by the indicator on the pump controller home
screen. The valve solenoid will not energize until the pressure switch contact has been made, notifying
the controller system pressure has been met. Once the opening sequence is complete and the system is
in normal operation, all system indicators can be seen in green.

5.3 Pump Malfunction

Anytime during the pumping operating when the pump discharge pressure is not capable of satisfying the
pressure switch setting, the visual indicator will turn red. This indicates a loss of pressure, the control
valve will close and the pump start contacts will open, turning the pump off. A “System Fault” indicator will
display on the screen. A manual reset of the emergency stop switch is required to clear the fault and
restart the pump.

Figure 15. PC-22D Controller Home Screen, Normal Operation.

Figure 16. PC-22D Controller Home Screen, Fault Indicator.

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To Reset a System Fault!

A system fault must be cleared using the emergency stop button. If the fault is not cleared, the pump will
not be able to start.

5.4 Valve Malfunction

If the solenoids of the pump control valve fail, or if any other event should cause the valve to close without
a normal pump shutdown command, the pump start contacts will open, turning off the pump. A “System
Fault” indicator will display on the screen. A manual reset of the emergency stop switch is required to
clear the fault and restart the pump.

5.5 Normal Stopping of Pump (Local and Remote)

A local pump stop command shall be initiated by pressing the stop pump button or by opening the remote
start contact. By initiating this command the pump control valve solenoid will de-energize and the valve
will start to close. Once the control valve is fully closed, the pump start contacts will open, shutting down
the pump.

5.6 Power Failure

In the event of a power failure, even momentary, it will take approximately one minute for the controller to
boot up. During the boot up process, it shall not be possible to have an automatic pump restart. After the
boot up process has been completed, a normal pump start sequence shall be initiated by using a local or
remote pump start command.

Valve Must be closed to prior to Pump Start!

A local or remote pump start will not be initiated unless the control valve is closed.

NOTE

WARNING

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5.7 Alarms

Various alarms can be programmed sending indication to SCADA there is a system failure. The
alarms/actions menu is accessed by using the 5 button keypad.

From the home screen, hold down the up arrow for more than 2 seconds to
access the alarms menu.

Select the “Actions” icon by using the button.

Various conditions can be programmed and sent to SCADA. To send a “fault” condition, program an
alarm as in figure 18. If the fault alarm is off, the variable fault equals 0, if a fault existed the fault variable
will equal 1. Outputs can be sent to SO1 (terminals 6 & 7) or SO2 (terminals 8 & 9).

Figure 17. PC-22D Controller, Alarms/Actions.

Figure 18. PC-22D Controller, fault alarm programming.

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6 Modbus Communication

The PC-22D Electronic Pump Control Panel comes standard with Modbus protocol. This protocol defines
a message structure that PLC’s will recognize and use, regardless of the type of networks over which
they communicate. The pump controller can be configured to communicate on standard Modbus
networks using either of two transmission modes: TCP/IP or RTU. Users shall have the ability to select
the desired mode, along with communication parameters (IP address, subnet mask, baud rate, etc). The
electronic valve controller shall have a built in VNC server. A viewer/client uses TCP port 5900 to
connect to a server (or 5800 for browser access), but can also be set to use any other port.

Supports Modbus TCP/IP and Modbus RTU simultaneously, as a server (slave) only.

Modbus RTU: requires UID (Modbus address, 1-255) and baud rate.

Modbus TCP/IP: requires allowed client IP address range (for access control) and IP port number
(default 502)

All data accessible with Modbus requests is mapped into the Holding Register address space (40000 to

65535). The commands supported are

• 03 – read multiple holding registers

• 16 – write multiple holding registers

Initially, only the physical inputs and outputs are available to a client. All share a common format, in
which an input or output is accessible as three consecutive 16-bit words. Remember that Modbus word
data is transmitted in Motorola format i.e. high-order byte: low-order byte.

Each input/output is represented as follows:

• Status/control word

• Input/output value (IEEE 32-bit float, high-order word:low-order word)

The status of the status/control word is common to all, but certain bits may never be set if they are not
applicable. Unused bits are read as zeros.

b0 signal lost/out of range (AIx and DIx_F only) read-only
b1 local override applied read-only
b2 alarm active (AOx, DOx only) read-only
b3 recopy active (AOx, DOx only) read-only
b14 clear Modbus override write-only, always reads as 0
b15 Modbus override active/set Modbus override read/write

Input/output values are expressed as natural units, so that if a 4-20 mA analog input is configured as
flow, where 4 mA = 10 l/s and 20 mA = 200 l/s, for an input value of 12 mA the client will read 95.

Space is reserved for 32 each of the analog inputs, digital inputs, analog outputs and digital outputs.
Reading an input/output which does not, physically, exist will return all zeros: writing has no effect. Note
that input values are supplied after any filtering, scaling and special handling. So reading the value of a
4-20 mA input which has no signal (defined as input < 3.6 mA) may return

• an out-of-range value

• the last-known good value

• a default value
depending on the configuration of the input. An input/output with a local override applied will return the
override value, not the current physical value.

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Cla-Val PC-22D Electronic Pump Control Panel

Installation, Operation & Maintenance Manual

Page | 24

Address mapping is as follows:

Analog Inputs

40000

Status/control word
40001

input value, high-order word
40002

AI1

Input value, low-order word
40003

Status/control word
40004

input value, high-order word
40005

AI2

Input value, low-order word
40006
.
.

AI3
.
.
40015

Status/control word
40016

input value, high-order word
40017

AI6

Input value, low-order word
40018-40099

Read as zeros

Digital Inputs

40100

Status/control word
40101

input value, high-order word
40102

DI1 (digital state 1/0)

Input value, low-order word
40103

Status/control word
40104

input value, high-order word
40105

DI1_C (counter value)

Input value, low-order word
40106

Status/control word
40107

input value, high-order word
40108

DI1_F (flow value i.e. counter
value over time)

Input value, low-order word
40109
.
.

DI2
.
.
40145-40147

DI6
40148-40150

DI6_C
40151-40153

DI6_F
40154-40199

Read as zeros

Analog Outputs

40200

Status/control word
40201

input value, high-order word
40202

AO1

Input value, low-order word
40203

Status/control word
40204

input value, high-order word
40205

AO2

Input value, low-order word
40206
.
.

AO3
.
.
40209

Status/control word
40210

input value, high-order word
40211

AO4

Input value, low-order word
40212-40299

Read as zeros

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Cla-Val PC-22D Electronic Pump Control Panel

Installation, Operation & Maintenance Manual

Page | 25

Digital Outputs

40300

Status/control word
40301

input value, high-order word
40302

DO1

Input value, low-order word
40303

Status/control word
40304

input value, high-order word
40305

DO2

Input value, low-order word
40306
.
.

DO3
.
.
40309

Status/control word
40310

input value, high-order word
40311

DO4

Input value, low-order word
40312-40399

Read as zeros

To override an input/output value, the client must perform a single write operation to all three words of the
input(s)/output(s) concerned. Any number of inputs/outputs may be overridden in the same write
operation, but the above condition must be respected.

To override a value the client must write

• status/control word, with b15 set to 1 (other bits will NOT be changed)

• high-order word of the new value

• low-order word of the new value

To clear an override the client must write at least the status/control word for the input/output concerned,
with b14 set to 1.

This means that with a single 18-word (6 x 3) write operation the client can override the values of
selected analog inputs (by setting b15 of the status/control word to 1), clear an override on others (set
b14 to 1), and leave the state of the rest unchanged (b14, b15 = 0).

NOTE that an override will have no effect if

• the write operation is incomplete (writing only 5 words to address 40200, for example, may

override AO1 but will have no effect on AO2)

• the supplied value is outside the permitted range

• a local override, an alarm, or a recopy is active

• if an override is applied and subsequently a local override, an alarm or a recopy become active,

the override is removed.

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Cla-Val PC-22D Electronic Pump Control Panel

Installation, Operation & Maintenance Manual

Page | 26

7 Pump Control Applications

The PC-22D Electronic Pump Control Panel is supplied with a pre-loaded pump control application on the
controller. This particular application uses both a pressure switch and valve limit switch.

There are many applications which do not require a pressure switch. If this is the case, the supplied USB
stick has an application with the pressure switch removed.

Pressure Switch!

If the alternative program is used, a jumper is still required across the pressure switch contacts.

To load an alternative program, using the 5 button keypad.

From the home screen, hold down the down arrow for more than 2 seconds.
Select “Application Management” icon.

Next, select the “Import Application” icon and load the appropriate application. The controller will restart.

NOTE

Figure 19. PC-22D Controller, settings menu.

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Cla-Val PC-22D Electronic Pump Control Panel

Installation, Operation & Maintenance Manual

Page | 27

8 Troubleshooting

1. Verify Input Connections

Note: All digital inputs are dry contact, 0 = Open Contact, 1 = Closed Contact

a. Before checks are made, remove both ice cube relays from socket to disconnect outputs.

b. From the home screen, click the “left arrow” button to view the input status.

c. Verify Local Start is recognized by controller – Put the HOA switch in “local” mode & press the

“Start Pump” button. When pressed, DI4 (Start Pump) should change from 0 to 1. This is a
momentary switch, when the “Start Pump” button is released the input will change back to 0.

d. Verify Local Stop is recognized by controller – Put the HOA switch in “local” mode & press the

“Stop Pump” button. When pressed, DI5 (Stop Pump) should change from 0 to 1. This is a
momentary switch, when the “Stop Pump” button is released the input will change back to 0.

e. Verify Pressure Switch Contact is Closed – Since a pressure switch is not being used, a jumper is

required across the contact. Verify the controller recognizes the closed contact (DI3 = 1).

f. Verify Limit Switch Contact Closure is Working Correctly – When the valve is closed, DI2 should

read 0 (open contact). When the valve is open, DI2 should read 1 (closed contact). Using a jumper,
verify the controller interprets a closed & open contact correctly.

g. Verify Emergency Stop is Working Correctly – Press in and out the emergency stop button & verify

DI6 is responding to each change.

h. Verify Remote Start is Working Correctly – Put the HOA switch in “remote” mode & close the

remote start contact. Verify DI1 (Pump Start) switches from 0 to 1.

Figure 21. PC-22D Controller, input status.

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Cla-Val PC-22D Electronic Pump Control Panel

Installation, Operation & Maintenance Manual

Page | 28

2. Verify Output Connections

i. Insert both ice cube relays back into sockets.

j. When the pump starts, verify there is a contact closure between 10 & 11. This is a non-powered

output from the factory.

k. When the valve solenoid energizes there should be 120VAC across 12 & 13.

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N-PC-22D (01/2019)

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