KELCO F40 Series Installing And Using

THE KELCO F40 DIGITAL PUMP CONTROLLER
WARNING
Please read this installation sheet fully and carefully. The F40 Digital
Pump Controller is a mains voltage device. Death or serious injury
may result if this product is not correctly installed and used.
INTRODUCTION
The F40 pump controller is a microprocessor based integrated pressure and flow
device. It is designed for controlling the operation of a pump and for protecting it
against running dry.
The F40 pump controller can be used in a variety of situations to control and
safeguard a pump. Some models can directly control single-phase pump motors
up to 5HP without the need for an interposing contactor. In addition to protecting
the pump from dry run damage the F40 can be set to automatically maintain line
pressure in stock watering applications or for cyclically pumping low yield stock or
domestic bores.
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WARNING
The F40 digital pump controller is water resistant to IP67. This rating
only applies if the clear control lid is in place and its two fixing
screws fully tightened. The F40 is not water resistant unless the clear
lid is in place and fully secured. Always replace the clear lid and
fully tighten its two screws after making changes to the settings.
The F40 may present a shock hazard and death or serious injury may
result if water enters the F40's electrical housing. There are no user
serviceable parts in this pump controller. Under no circumstances
should the main housing be opened. Warranty on this product is
automatically void if the sealed body screws are opened.
IMPORTANT
This installation and usage information sheet must be read with reference to the
specific model controller being installed. The power switching capacity and the
pressure rating of the controllers vary from model to model and it is very important to
understand the limitations of a specific controller before installing it.
MODELS
F40 - 240 - S - 5
SUPPLY VOLTAGE
240 = 220 TO 240VAC
24 = 24V AC or DC
NO LETTER = 10Amp PLUG & PLAY
HD = HEAVY DUTY 15Amp CABLES 2 X 2M LONG
S = SINGLE CABLE 2M LONG WITH 4 or 5 CORES
OPERATING ENVIRONMENT ALL MODELS
Supply F40-240 & F40-240-HD
Supply F40-24 Low Voltage AC/DC Model
Ambient Temperature Range
Liquid Temperature Range
Ingress Protection Rating
Maximum Operating Pressure
INSTALLING AND USING
CABLE CORES
4 = 4 CORE 10Amp CABLE
5 = 5 CORE 6Amp CABLE
CABLE
220 to 250VAC 50Hz Single Phase
12 to 28V AC or DC at 80mA Max.
1ºC to 50ºC
1ºC to 60ºC See note below
IP67
20 Bars 300psi
OPERATING RANGE ALL MODELS
Start-up Timer Adjustable from 1sec. to 3 minutes in 15 steps
Run-on Timer Adjustable from 1 sec. to 5 minutes in 15 steps
Restart Timer Adjustable from 1 min. to 48 hours in 15 steps
Pump Start Pressure Range 0 to 5 Bars in 16 steps of 33kPa each
Maximum Starting Pressure 500kPa (72 psi)
Minimum Starting Pressure 33kPa (4.7 psi)
Recommended Pipe Sizes 25mm (1") or larger. (There is no upper limit)
Maximum Switched Load 250VAC 50Hz 2.4kW (Motors up to 3HP)
F40-240
Maximum Switched Load 250VAC 50Hz 3.75kW (Motors up to 5HP)
F40-240-HD
Maximum Switched Load F40- 250VAC 50Hz 2.4kW (Motors up to 3HP)
240-S-4
Maximum Switched Load F40- 250VAC 50Hz 6Amps Non Inductive
240-S-5
Maximum Switched Load 250VAC 50Hz 6Amps Non Inductive
F40-24-S-5
Operating Pressure Range, 0 to 20 Bars (0 to 300psi) See Note Below
Static or Dynamic
Burst Pressure 50 Bars (750 psi)
NOTE: The F40 pump controller must NOT be used in hot water applications (>60ºC). The
F40 pump controller is rated to withstand water pressure to 20 Bars (300 psi) and must
not be used in applications where the static or dynamic pressure exceeds this rating.
INSTALLATION
The F40 is suitable for use in all cold-water based applications such as potable water,
seawater, bore water, chlorinated pool water, brackish water or filtered effluent. A
suitable location should be selected for the controller in the delivery pipework of the
pump. The controller should be installed in a location that is away from both vibration
and heat, preferably out of direct exposure to the weather and above any flood level.
A 1" BSP socket, or threaded pipe tee must be provided in the pipework to fit the
controller. The controller should be located on the topside of a horizontal section
of the pipe work with a minimum of 2 diameters of straight pipe either side of the
controller. Under no circumstances mount the F40 under a pipe or close to valves,
tees, bends or any other obstructions likely to cause major turbulence in the flow.
The F40 can be mounted in vertical pipework if required, and flow can pass either in
an upward or downward direction.
In most installations the paddle of the F40 will need to be trimmed to suit the specific
pipe tee in which it is to be installed. The paddle of the controller needs a force
equivalent to 20 grams dead weight acting on it from the flow in order to operate
correctly. The force is generated by water in motion pushing against the exposed
area of the paddle. The more area of paddle exposed to the flow the more force
available to actuate the controller. Be aware that high velocity flow can generate high
forces and may damage the paddle. As a general guide the paddle of the F40 should
extend to slightly past the centre line of the pipe. The paddle would not normally
be left longer than this unless the expected flow rate was very low. If you know the
likely flow rate and the pipe size of your pump system there is an online calculator
available at www.kelco.com.au that will help you to work out an exact size to cut
the paddle. Use tin snips, side cutters or a hacksaw to cut the paddle. If needed, cut
away the sides of the paddle so it clears the pipe socket and pipe walls by at least
4mm at its closest point. Apply a suitable thread sealant tape or paste and screw
the F40 into the socket using the spanner flats provided. When properly installed
the controller should be square to the axis of the pipe, with the flow arrow on the
side of the F40's body correctly oriented and parallel to the line of flow. In addition,
there should be a gap of at least 4mm between the top of the 1"BSP pipe socket
and the under edge of the F40's spanner flats. Under no circumstances should the
F40 be wound into the pipe socket until its thread bottoms out in the socket as to do
so places the thread in tension and may result in the controller's housing cracking
under pressure.
HOW TO INSTALL AN F40 DIGITAL PUMP CONTOLLER
1"BSP REDUCING BUSH
MINIMUM OF 2 DIAMETERS
OF STRAIGHT PIPE EACH
SIDE OF THE F40
4mm MINIMUM GAP
STANDARD PIPE TEE
CUT PADDLE TO CLEAR THE
PIPE BY A MINIMUM OF 4mm
ALL ROUND