INTRODUCTIONThank you for purchasing Cla-ValModel PC-1 Pump Control Panel.The Cla-Val Model PC-1 PumpControl Panel (P/N 2444901K) pro-vides electrical interlock controlbetween Cla-Val Pump ControlValve and pump with simple fieldhook-up and easily adjusted pumpstarting and stopping sequencesteps. It is suitable for BoosterPump and Deep Well Pump appli-cations. For detailed operationinformation see Cla-Val engineeringdata sheet E-PC-1 included withthis manual.

Personnel installing or using this equipment should read entiremanual (and any other included documents) to become familiarwith requirements for installing or operating the PC-1.At a minimum, you should follow all applicable sections of the

National Fire Code, National Electrical Code, and NationalElectrical Manufacturer’s Association Standards. There may belocal regulatory or governmental offices that can also help deter-mine which codes and standards are necessary for safe installa-tion and operation.

INSTALLATIONThe installation should provide proper ventilation, spacing, andgrounding techniques to help minimize the risk of potential prob-lems. Recommended mounting of the PC-1 is on vertical surfaceat a convenient location near pump motor panel. Conduit shouldbe routed to the bottom of enclosure for easy hook-up to internalfield wiring terminal strip. Use appropriate size hole saw to cut onlythe required number of holes in enclosure bottom. In order tomaintain the watertight integrity of the enclosure, only watertightconduit connectors should be used.

WIRINGConsider the following wiring guidelines before you install any sys-tem or power wiring. For specific information on wiring, refer toproduct specification sheet or National Electrical Code require-ments. There may be local regulatory or governmental offices thatcan also help determine which codes and standards are necessaryfor safe installation and operation.

• Always use continuous length of wire. Do not combine wires to attain a needed length.

• Use the shortest practical cable length.

• Avoid running wires near high energy wiring.

• Avoid running input wiring in close proximity to output wiring where possible.

• Avoid creating sharp bends in the wires.Input PowerProvide 5 amp fused 120/60 VAC input power for PC-1 at terminals1 and 2. Provide protection from AC power voltage spikes, elec-tro-magnetic interference (EMI), and lightning strikes according to

all applicable electrical wiring codes. Be sure to properly connectearth ground to green terminal.

Noise SuppressionAC power voltage spikes, electro-magnetic interference (EMI),lightning strikes, and AC-powered solenoids coil activation createelectrical "noise" that can affect PC-1 controller operation. Noisesuppressors are necessary for optimum PC-1 operation. MOVnoise suppressors should be installed on PC-1 power input at ter-minals 1 and 2 and on power (red) wires of valve solenoid(s) asclose to the solenoid coil as practical. Cla-Val offers an optionalNoise Suppressor (p/n 2696336D) rated RC Snubber (MOV-type),250 VAC, 70 Joules, one-piece with tinned leads.

FUSESThe PC-1 is supplied withfour fuses for the poweredoutput circuits. They arefound in fuse holdersmarked F1, F2, F3, andF4. Prior to replacing anyfuse all power to the PC-1must be turned off.Replace fuses with 10 mmx 0.38 mm fuses of theproper current rating.

• Fuse F1 is rated 10 A and is on NON-POWERED Pump MotorStart Command Circuit

• Fuse F2 is rated 1A and is on Valve E-Stop Solenoid Output Circuit

• Fuse F3 is rated 1A and is on Valve Pilot Solenoid Output Circuit

• Fuse F4 is rated 1A and is on Loss of Power Restart Delay Alarm Output Circuit

INPUTSThe PC-1 control inputs are:

MANUAL/LOCAL STARTTo initiate a pump start, place the H-O-A switch in Hand positionand press the green Start switch. Pump will continue to run untilred Stop switch is pressed to initiate a normal pump shutdown.When H-O-A switch is in Off position the PC-1 will not initiate astart sequence manually (local) or automatically (remote).

AUTOMATIC/REMOTE STARTTo initiate a pump start, the PC-1 receives a pump start signal froma remote source such as a SCADA controlled RTU panel or a pres-sure switch. With the H-O-A switch in Auto a contact closure willinitiate a pump start. Pump will continue to run while contacts areclosed. Contact opening or positioning the H-O-A switch to Off willinitiate a normal pump shutdown.

VALVE LIMIT SWITCHThe Normally Open and Common contacts of pump control valvelimit switch are used for signaling valve position to the PC-1.These contacts are closed when valve is closed (or when valve is

PC-1Pump Control Panel

MODEL

INSTALLATION / OPERATION / MAINTENANCE

open for deep well pumps). The valve limit switch is adjusted toactuate when the valve is in closed position (or open for deep wellpumps). For valve switch adjustment procedure, see Cla-ValModel X105L Valve Limit Switch Assembly data sheet in technicalmanual for pump control valve.

DISCHARGE PRESSURE SWITCHIn order to use the pressure-related functions of the PC-1, anoptional customer supplied pressure switch must be installedbetween pump discharge and control valve inlet. The NormallyOpen contacts of the pressure switch are used (contacts closewhen pressure setting is reached or exceeded). If a pressureswitch is not used, a factory supplied jumper must be installedacross terminals 9 and 10. Remove jumper when installing pres-sure switch.

ANTI-PLUGGING PUMP SWITCHSome pumps have built-in contacts to indicate pump motor shaft isrotating (forward or backward) when no electric power is applied.These Anti-Plugging Pump Contacts are used for signaling to thePC-1 that pump is rotating. These contacts are closed when pumpis rotating and keep PC-1 from initiating a start sequence andpotentially causing pump damage.

LAMP TEST/ALARM RESET SWITCHMomentarily pushing of this switch will test all indicator lampswhen power is on (they will all light while the switch is depressed).A 5 to 10 second push of this switch will reset (or acknowledge)any alarm light signal and all lights will go off (white light remainson). If the alarm condition is not corrected after acknowledgmentby this switch, the alarm will again trip.

EMERGENCY STOP SWITCHThis push-pull, snap-action switch will remove all power to PC-1outputs when pushed IN. The internal PLC remains powered.When switch is pulled OUT the PC-1 will operate normally. Theswitch must "click" into place. Activating this switch requires aheavy manual force.

OUTPUTSThe PC-1 control outputs are:

1. Valve Pilot Solenoid Output Control Circuit (120/60 VACpowered)

2. Valve E-Stop Solenoid Output Control Circuit (120/60 VAC powered)

3. Pump Motor Start Command Circuit (non-powered but fused)

4. Failure to Develop Pressure Remote Alarm Output Circuit (non-powered)

5. Loss of Pressure Remote Alarm Output Circuit (non-powered)

6. Valve Failed to Open Remote Alarm Output Circuit (non-powered)

7. Valve Reclosed Remote Alarm Output Circuit (non-powered)8. Loss of Power Restart Delay Alarm Output Circuit (120/60

VAC powered)9. H-O-A Switch in Auto Position Remote Contacts Output

Circuit (non-powered)

TIMERSThe PC-1 is supplied with three field adjustable timers. Thesetimers provide easy-to-set adjustment of pump start sequencesteps. In case of mechanical trouble with pump, control valve, orsystem, these timers keep PC-1 from completing a start sequence.

Timer T1 is LOSS OF POWER AUTOMATIC RESTART DELAYTIMER. After a loss of power, an automatic pump restart will occurupon the expiration of timer T1 provided that:

a. The H-O-A switch is in Automaticb. A signal is present to start the pump remotely (terminal 12 and 13)c. The valve indicates closed (via valve position switch at

terminals 10 and 11)

NOTE: Automatic restart is disabled by removing jumper from ter-minals 14 and 15.

Timer T2 is PRESSURE DELAY SEQUENCE TIMER (PDST).Upon initiation of a pump start command, the PDST is energized.The pilot valve solenoid is energized upon expiration of the PDST.In booster pump applications, this time maybe used to allow thepump to develop discharge pressure before opening the pumpcontrol valve. In deep well pump applications, the time may beused to flush the system prior to closing the valve and placing thepump on the system.

Timer T3 is VALVE SEQUENCE TIMER (VST).The VST is energized when the pilot valve solenoid is energized.

If the valve fails to open (close for deep well pumps) prior to theVST expiring, an automatic shutdown will occur.

SETTING TIMERS T1, T2, and T3The Cla-Val PC-1 Pump Control Panel is supplied with three fieldadjustable timers (time delay relays) marked T1, T2, and T3. Aftersetting desired time delay, during the pump start sequence poweris applied to relay coil and control contacts remain open and power(PWR) light is on. After preset time has elapsed, relay shifts toclose contacts and out (OUT) light is on. Reset occurs whenpower is removed by PLC inside PC-1.

There have been three different styles of time delay relays used forT1, T2, and T3. Each style of relay has different setting instruc-tions depending on date of PC-1 manufacture.

A. Prior to January 1998, the timers were an orange cube-style(Syrelec Model OAR2U delay on make) with an adjustable rangeof 0.1 sec to 10 hours and used these instructions for setting timedelay.

1. Select Hours, Minutes, or Seconds with the Time Base Selection Switch on the lower right-hand front. Use a smallscrewdriver (4 mm maximum width) to move switch up or down and view desired setting in window above switch. Make sure switch clicks or snaps into place.

2. Select desired multiplier (x0.1 or x1) by moving Scale Selection Switch located to the left of the time base switch.Make sure switch clicks or snaps into place.

3. Rotate Dial (for 0 to 10 units) to desired time delay setting within the Time Base range and Scale multiplier selected.

B. Between January 1998 and January 2004, the timers were ablue cube-style (IDEC Model RTE-P12) and used these instruc-tions for setting time delay.

1. Select desired maximum time range using only Time RangeGroup 2 in following table. Table is also on bottom side of relay. M = minutes, H = hours

2. Remove thin plastic dial faceplate. Use a small screwdriver(4 mm maximum width) under lip at bottom center to carefully pry faceplate off relay top. Do not remove knob.

3. Digital Switch is located on lower left corner of relay top face.Adjust digital switch up or down with a small screwdriver untildesired time range number is displayed in window.

4. Mode of Operation switch is located on upper left corner of relay top face. This switch must be kept in the right-hand position for "Delay on Make" operation.

5. Rotate inner portion of plastic dial faceplate until desired time range and units show in faceplate windows. You may have to turn plastic dial over to find desired range and to match dial color. Refer to above chart. Reinstall plastic dialon top of relay by inserting top edge tabs into top slots. Bend the dial faceplate slightly as it is placed over knob andinsert the bottom edge into the bottom slot of the timer. As dial faceplate "snaps" into place at the top, make sure that inner dial remains in place.

6. Use center knob to set amount of time delay desired within the range selected.

C. Starting in January 2004, the timers were changed to a bluecube-style (IDEC Model RTE-P1AF20) and use these instructionsfor setting time delay.

1. Select desired time range using following table. Set Time Range Selector and Dial Selector at bottom of relay face tocorresponding positions for desired time range. Use a smallscrewdriver (4 mm maximum width) to turn selectors. Makesure switch clicks or snaps into place. DO NOT FORCE BEYOND END POSITION.

2. Mode of Operation switch is located on lower left corner of relay top face. This switch must be kept in the ”A” mode position for "Delay on Make" operation.

3. Use center knob to set amount of time delay desired within the range selected.

FIELD WIRING HOOKUP TERMINALSThe following describes the input and output terminals of PC-1panels built since January 1996. Refer to Field Wiring Hookup dia-gram Cla-Val drawing 204377 included with this manual.

A.) Terminals 1, 2 and Ground are for connecting 120 Volt 60HzAC (5 Amp fused) power (customer supplied). This is for power to the PC-1 itself. Terminal 3 is NOT used.

B.) Terminals 4 and 5 are dry-contacts (N.O. rated: 120 VAC, 10Amp - fused at F1) for connection to customer supplied pump motor starter circuit.

C.)Terminals 6 and 7 have 120 Volt AC power (up to 1 Amp - fused at F2) present (the PC-1 will energize these when needed) and are to be connected to the Emergency ClosingSolenoid on the control valve (if present).

D.)Terminals 7 and 8 have 120 Volt AC power (up to 1 Amp - fused at F3) present (the PC-1 will energize these when needed) and are to be connected to the Pilot Valve Solenoidon the control valve.

E.) Terminals 9 and 10 are dry-contact type (24 volt DC, 10 Milliamp) for connection to customer supplied no-voltagecircuit to Pressure Switch (N. O. contact and Commoncontact) located between pump output and valve inlet (if present).

F.) Terminals 10 and 11 are dry-contact type (24 volt DC, 10 Milliamp) for connection to customer supplied no-voltagecircuit to Cla-Val Model X105L Valve Limit Switch (N. O. contact and Common contact) mounted on the valve.

G.)Terminals 12 and 13 are dry-contact type (24 volt DC, 10 Milliamp) for connection to customer supplied no-voltage circuit to provide Remote/Automatic Start with the PC-1. When these contacts are "made" and with the H-O-A switchin Automatic, the PC-1 will initiate a start of the pump and continue to allow the pump to run until this contact is broken.

H.)Terminals 14 and 15 are for allowing automatic Loss of Power Restart with the jumper installed (standard). PC-1 will automatically initiate a pump start after power is restored. If the jumper is not present, the PC-1 will not initiate a pump start when power is restored after a loss of power. A manual reset with the Lamp Test/Reset switch (30-sec. minimum) will be needed to restart the pump after power is restored.

J.) Terminals 16 and 17 are dry-contact type (N.O. rated: 1 Amp, 120 VAC) for connection to customer supplied circuit

Digital SwitchPosition

Time Range GroupDial Color

1 2

0, (or 8) 1 S 1 M Blue1, (or 9) 3 S 3 M Violet

2 6 S 6 M Violet3 10 S 10 M Blue4 60 S 60 M Violet5 30 S 30 M Violet6 5 M 5 H Blue7 10 M 10 H Blue

Range0 - 1scale

0 - 3scale

0 - 10scale

0 - 30scale

0 - 60scale

s 0.1 s-1 s 0.1 s-3 s 0.2 s-10 s 0.6 s-30 s 1.2 s-60 s

min 1.2 s-1 m 3.6 s-3 m 12 s-10 m 36 s-30 m 1.2 m-60 m

h 1.2 m-1 h 3.6 m-3 h 12 m-10 h 36 m-30 h 1.2 h-60 h

10 h 12 m-10 h 36 m-30 h 2 h-100 h 6 h-300 h 12 h-600 hs = seconds, m = minutes, h = hours

for remote signal alarm of Failure To Develop Pressure.

K.) Terminals 18 and 19 are dry-contact type (N.O. rated: 1 Amp, 120 VAC) for connection to customer supplied circuit for remote signal alarm of Loss Of Pressure.

L.) Terminals 20 and 21 are dry-contact type (N.O. rated: 1 Amp, 120 VAC) for connection to customer supplied circuit for remote signal alarm of Valve Fail To Open.

M.)Terminals 22 and 23 are dry-contact type (N.O. rated: 1 Amp, 120 VAC) for connection to customer supplied circuit for remote signal alarm of Valve Re-Closed during start sequence.

N.)Terminals 24 and 25 have 120/60 AC power (N.O. up to 1 Amp - fused at F4) present when an alarm condition exists and are for connection to customer supplied circuit for remote signal alarm of Loss Of Power Restart Delay. Typically, this would activate a relay for the alarm signal.

O.)Terminals 26 and 27 are dry-contact type (N.O. rated: 1 Amp, 120 VAC) for connection to customer supplied circuit for remote signaling of the H-O-A switch being in the "Auto"position. When the H-O-A switch is in the "Auto" position,

no power contact is "made" at these terminals.

P.) Terminals 28 and 29 are dry-contact type (24 volt DC, 10 Milliamp) for connection to customer supplied no-voltage circuit to provide an "Anti-Plugging" input signal from the pump (if so equipped) when the pump is coasting or spinningin reverse. When these contacts are "made" from the pump,a start sequence will not be allowed.

OPERATION CHECK OUT AND BENCH TESTThe following steps are for a PC-1 operation check out and benchtest. This test is for newer PC-1 panels built since January 1998and that have on the lid face the following: a) Lamp-test/Resetswitch, b) H-O-A switch mounted to the left-of-center, c) lid has redand blue color markings on white background, and d) inside thePC-1 is an Automation-Direct brand modular-style PLC. PC-1’sbuilt before September 1996 used an Omron brand dedicated PLCfor internal control sequencing and does not follow this sequenceexactly.

Preparation:A.) PC-1 hooked up to 120/60 VAC at terminals 1, 2, and Ground.B.) No other inputs or outputs hooked up to the PC-1.C.) Set Time Delay Relays TR1, TR2, and TR3 to zero time.D.) H-O-A switch is in OFF position.

The following steps occur when power is applied:1. On the lid, the white panel light (Power) goes on.2. On the inside, the CPU module PWR and RUN green

indicators go on.

3. On the inside, the Input module red indicators A0, A7, and B0 go on (use A/B selector switch to switch between A and B series).

4. On the inside, the TR1 relay ON and OUT lights are on.

NOTE: If the white panel light does not go on, then the E-STOPswitch is depressed. Lifting the E-STOP switch will turn on whitepanel light. The switch must "click" into place.

NEXT, turn the H-O-A switch from OFF to HAND, then push green(Start) button. Watch for:

1. On the lid, the blue panel light (Pressure) goes on and about three seconds later the green panel light (Valve Open) goes on.

2. On the inside, the Input module red indicator lights A3, A5, A6, A7, B0, and B4 go on.

3. On the inside, the TR1, TR2, and TR3 relay ON and OUT lights go on.

4. On the inside, the CR1 relay red indicator light goes on.

NOTE:a) To verify that panel lamps are functionary properly, depress

and hold Lamp Test/RESET button. All five panel lights goon for about three to five seconds and then go off.

b) If the amber panel light (Restart/Delay) flashes, then depress the Lamp Test/RESET button for at least 30 seconds to reset the PC-1. You may hear some relay clicking from inside the PC-1, this is normal. If AC power to terminals 1, 2, and ground are removed for 30 seconds, the PC-1 will also reset.

c) If the Lamp Test/RESET button is released before completereset, then when the HOA switch is turned from OFF to HAND (or if it was already in HAND), AND then Start buttonis pushed, the amber panel light will flash. A complete 30 second reset will turn off flashing amber panel light.

d) If the Lamp Test/RESET button is released before completereset and the amber panel is flashing, THEN when the E-STOP switch is depressed and then lifted, the red panel light goes on and the amber panel light will continue to flash.A complete 30 second reset will turn off red panel light and flashing amber panel light.

CLA-VAL Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice. P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

© N-PC-1 (R-1/08)

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CLA-VAL Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice. P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

© N-PC-1 (R-1/08)