KELCO F30 Installation And Operating

INSTALLATION AND OPERATING OF F30 PUMP CONTROLLERS
The F30 pump controllers require both electrical and mechanical
fitting. Installation or servicing of these controllers should only be
carried out by competent qualified personnel familiar with hydraulics,
pump fitting and with electrical control circuitry.

GENERAL NOTES

The F30 pump controllers are normally used to give dry run protection to
pressure pump systems. By using the system's existing pressure switch,
a normal pressure start pressure stop pump can be converted to either
a pressure start flow stop or a flow start flow stop system. This gives
some major benefits in the way the pump performs in comparison to a
conventional pressure start pressure stop pump system. In addition to dry
run protection, such a system will supply a relatively constant pressure,
free from the cyclic pressure fluctuations that are characteristic of normal
pressure systems. No pressure cycling means a small draw off air cell
can be used, even on a large pump. Before installing the F30, a basic
decision needs to be made as to how you want the pump to operate. The
F30 can be mounted before or after the air cell to achieve totally different
operating characteristics.

INSTALLING THE F30 BEFORE THE AIR CELL

If the F30 is installed between the pump and the air cell and a tap is
opened, the air cell will supply the demand, large or small. The pressure
will drop and eventually the pressure switch will close, starting the
pump and supplying the demand. In other words there will be a delay
between turning on a tap and the pump starting. This delay will depend
on the draw off capacity of the air cell and the demand flow rate. This
configuration has the advantage that the pump will not start every time
a tap is turned on, but only if there is a genuine sustained demand for
water. This configuration is what is meant by "pressure start flow stop".
This configuration is ideal for large pumps where there may be small or
frequent demands, such as in communal wash rooms. A large draw off
air cell is often used in such systems to further reduce the pump's start
stop frequency.

INSTALLING THE F30 AFTER THE AIR CELL

If a tap is opened too much more than a trickle with this configuration,
the pump will immediately start, due to the paddle of the F30 being
pushed forward by the flow from the air cell. This is what is described
as "flow start". With this arrangement the only time the system will
start on pressure drop is if there are leaks in the piping or a tap is left
trickling. In such a situation, the pump will automatically start when the
pressure switch eventually closes, re-pressurise the system and stop
after a time delay, under the control of the F30. The main advantage of
installing the F30 after the air cell is that the system will give an instant full
pressure start at a very constant flow every time a tap is turned on. This
configuration is ideal for small irrigation systems, gardens and household
use. Where a gravity fed hot water system is installed, the hot and cold
cycling in showers that plague normal pressure pumps are eliminated
with this configuration.

INSTALLATION

Having decided which basic configuration to use, follow the notes below.
Set out are some circuit examples and some essential details on installing
and adjusting the F30.
A suitable location should be selected for the controller in either the suction
or 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 or larger
socket must be provided in the pipework to fit the controller. The socket
should be located on the topside of a horizontal section of the pipe with
at least 5 diameters of straight pipe either side of the controller. Under
no circumstances mount the controller upside down under the pipe, or
close to valves, tees, bends or any other object likely to cause major
turbulence in the flow.
ISOLATION VALVE
FLOW
SUCTION PIPE CHECK VALVE
TYPICAL LARGE INDUSTRIAL OR RURAL PUMP INSTALLATION
PUMP
AIR CELL
BLEED VALVE
PRESSURE
F30HD
SWITCH
ISOLATION
In most installations the paddle of the controller will need to be trimmed
to suit the specific pipe in which the unit is to be installed. The paddle of
the controller needs a force of around 15 to 20 grams acting on it from
the flow in order to operate correctly. High velocity flow can generate high
forces and damage or break the paddle. As a general guide the paddle
of the controller should extend to around the centre line of the pipe, or
a bit past the centre. The paddle would not normally be left longer than
this unless the expected flow velocity was very low. Cut the paddle so
it extends to about the centre line of the pipe, or a little past the centre
when screwed into its socket. Ensure the paddle will clear the sides of
the socket and has enough room to swing back and forward freely. Apply
Teflon tape or a suitable thread sealant and screw the controller into the
socket using the spanner flats provided. Do not twist the body of the
controller or use it to screw the unit into the socket, as to do so may
damage the housing. When properly installed there should be a gap of
at least 4mm between the top of the 1"BSP thread and the under edge
of the spanner hexagon. Under no circumstances should the thread
be allowed to bottom out in its socket as to do so places the thread in
tension and may result in the controller housing cracking under pressure.
A quick release fitting can be used between the F30 and the pipe tee,
as shown in the accompanying drawing. This makes maintenance and
removal very simple.
CONTROLLER MOUNTED IN THE MIDDLE OF 10 DIAMETERS OF STRAIGHT PIPE
F30 MOUNTED IN A QUICK RELEASE COUPLING
PRESSURE
SWITCH
PUMP
F30HD MOUNTED BEFORE THE AIR CELL
F30 INSTALLED BEFORE
THE AIR CELL
VALVE
SERVICE
4mm MINIMUM
SEE NOTES
PADDLE CUT TO HALF WAY
ACROSS PIPE
PREFERED LAYOUT, WITH PIPE WORK HORIZONTAL AND LEVEL
F30 MOUNTED IN A PIPE TEE
40 BY 25 REDUCING BUSH
4mm MINIMUM
ANKA QUICK COUPLING
QLCM40 & QLCF40
PADDLE CUT TO HALF WAY
ACROSS PIPE
AIR CELL
F30HD
DISCHARGE
SUCTION
F30HD MOUNTED AFTER THE AIR CELL
F30 INSTALLED AFTER
FLOW
FLOW
AIR CELL
F30HD
DISCHARGE
PRESSURE
SWITCH
PUMP
SUCTION
THE AIR CELL