Related Manuals for KELCO F29 MK3
Summary of Contents for KELCO F29 MK3
- Page 1 KELCO F29 MK3 DIGITAL PUMP CONTROLLER INSTALLATION & PROGRAMMING MANUAL KELCO Engineering Pty Ltd Sydney Australia www.kelco.com.au...
- Page 2 VERY IMPORTANT SAFETY NOTICE PLEASE READ THIS BEFORE INSTALLING THIS CONTROLLER The F29 MK3 is an industrial control device. It is specifically designed for use in industrial, agricultural and mining applications. It must never be used for any application other than for the aforesaid purposes. The installation, commissioning of this pump controller requires extensive knowledge of pump engineering and electrical engineering.
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Page 3: Important: Read This First
IMPORTANT: READ THIS FIRST DO NOT EXPOSE THE F29 MK3 TO VIBRATION. INSTALL ONLY IN PIPEWORK THAT DOES NOT VIBRATE. Vibration will damage the electronics within the F29 and will void your product warranty. This F29 programmable flow switch has been fully tested and calibrated. It is set to operate in a basic way with most of its special functions and features switched off. - Page 4 LCD SCREEN BACKLIGHT The LCD backlight can be turned on or off. To turn the light off press and hold down the (v) button. Press and release the (R) button. Release the (v) button. Repeat to turn the light on. The light remembers the state it was last left in, if power is turned off.
- Page 5 4) Do not expose the thermoplastic F29-S to static or dynamic pressures greater than 18 Bars, 261 psi. Do not expose the stainless steel F29-SS to static or dynamic pressures greater than 200 Bars, 2900 psi. 5) Do not install the F29 in a section of pipe that is subject to vibration. Vibration will cause premature failure of the electronic components within the F29.
- Page 6 F29 should be installed in a straight section of pipe preferably with 5 diameters of straight pipe either side of the paddle. The F29 can be installed in a suitable pipe socket, tapping saddle or pipe tee. The F29 can be installed in either the suction or discharge pipework of the pump.
- Page 7 BEFORE THE AIR CELL If the F29 is installed before the air cell, it will only start the pump on pressure drop via an external pressure switch since the initial draw off will be supplied from the air cell and will not push the paddle of the F29 into its on position.
- Page 8 AFTER THE AIR CELL If you install the F29 in the pipework after the air cell the flow switch will start the pump each time flow from the air cell pushes its paddle forward or each time pressure falls to whatever pressure you have set the external pressure switch to start at.
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Page 9: Installation
If you know what the expected flow rate is the calculator allows you to enter your pipe diameter and paddle dimensions. It will then determine if the selected paddle dimensions are adequate for the application. Spare paddles to suit the F29 MK3 are available from Kelco or from your distributor. - Page 10 VERY IMPORTANT SAFETY NOTE A pressure relief valve should be fitted to any system that can exceed the pressure rating of any component on that system. Alternately, always confirm that the pressure safety limits of individual items are compatible and not compromised without the fitting of appropriate safety devices, i.e.
- Page 11 connection. A matching female threaded socket, pipe saddle or pipe tee must be provided to fit the F29 into the pipework. ATTACHING THE ELECTRICAL HOUSING There is a flat keying face on the cylindrical body of the paddle assembly that keys the electrical housing onto the paddle assembly and aligns it correctly.
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Page 12: Electrical Installation
The paddle will become increasingly more sensitive and will respond to progressively lower flows the further out you wind the adjusting screw. The total adjustment range is 10 turns of the screw. If you wind the adjustment screw out beyond 10 turns there will not be enough residual force to return the paddle to the off position when flow stops. - Page 13 utilising the low voltage active terminal LV and neutral terminal N (see the included wiring diagrams). When operated from a low voltage DC supply the terminals LV and neutral N are not polarity sensitive. Pay attention to cable sizes and ensure cables are adequate for the specific pump motor load.
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Page 14: Brownout Or Blackout
WARNING The HD terminal must be left unused or only ever linked to Relay 1 Normally Open. It must never be used for any other purpose and it must never be connected to any external device. Under no circumstances connect the HD terminal to the terminals of Relay 2. The HD terminal must be regarded as live at all times and at full mains potential. - Page 15 Crimp the ears of the strain relief ring onto the cable and pull the cable back into the slots in the gland housing. Controller Housing Rubber Plug Backing Washer Rubber Grommet Backing Washer Cable 7mm to 9mm diameter M20 Gland Nut Plug unused cable glands using the rubber plugs...
- Page 16 POWER REQUIRED TO DRIVE THE STANDARD F29 24VDC Supply to LV & N Maximum 68mA 1.63Watts 24VAC 50Hz Supply to LV & N Maximum 108mA 2.34Watts 220VAC 50Hz Supply to A & N Maximum 87mA 2.00Watts 240VAC 50Hz Supply to A & N Maximum 94mA 2.54Watts POWER REQUIRED TO DRIVE THE 12VDC F29-12 With Both Relays Closed...
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Page 17: Remote Input
REMOTE INPUT WARNING: The low voltage source available at the LV terminal is non- isolated and must be regarded as operating at full mains potential whenever the F29 is powered from the mains. Relative to earth, the LV terminal is at mains potential. - Page 18 EXAMPLE A water tank is located 2000 metres from the F29. Two separate wires each 0.2mm^2 are run to the remote tank (total wire length is 4000 metres). The resistance as measured across the 2 wires back at the F29 (with the tank level switch closed) is 382 Ohms.
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Page 19: Wiring Diagrams
WIRING DIAGRAMS PLUG & PLAY CONNECTIONS CONNECTIONS FOR A SINGLE PHASE PUMP Optional voltage free external input All electrical wiring associated with this controller must be carried out by a qualified Electrician Earth Link... -
Page 20: Low Voltage Supply
DUAL SINGLE PHASE PUMPS & 2 REMOTE INPUTS Supply 110 ~ 240VAC 50 This link wire must be used whenever the controller is directly controlling a single Active phase pump motor, as shown. Do NOT use the HD link in 3 phase or single phase control circuit applications Neutral Remote switches with Pump Motor 2... - Page 21 BASIC 3 PHASE PUMP CONTROL Contactor WARNING Contactor coil rating must not exceed 240VAC 3 Phase Pump Motor DUAL 3 PHASE PUMP CONTROL Contactor 1 3 Phase Pump Motor 1 Contactor 2 WARNING 3 Phase Pump Motor 2 Contactor coil rating must not exceed 240VAC...
- Page 22 3 Phase Pump Motor THE 12VDC F29 FLOW SWITCH A low voltage DC version of the F29 MK3 is available for battery operation and for use in solar pumping systems. Functionally the 12V DC model is the same as the mains voltage model except for the terminal block markings. On the 12VDC model the active and neutral terminals are replaced by a positive + and a negative –...
- Page 23 120 ~ 240VAC 50/60Hz Pump Motor 2.4kW Max. when the HD terminal is linked PROGRAMMING THE F29 MK3 For a description of the functions of the buttons and lights please read pages 2 and 3 of this manual before proceeding.
- Page 24 Kelco www.kelco.com.au This is the first screen in the menu. Press and release (P) again. F29 MK3 Controller Version 000000 The version number must match the number on the cover of this book. Press and release (P) again.
- Page 25 USE REMOTE INPUT If a remote input switch is connected to the F29 select yes to this question by pressing the button. Press the (P) button to lock your choice into memory and to move to the next screen. You are then presented with a choice of 3 ways the remote input can be configured.
- Page 26 CLOSED ON FLOW OPENS ON NO FLOW The relay contacts mimic the action of a simple on/off flow switch. START ADDITIONAL EQUIPMENT This option works in conjunction with pre-start delay timer to allow control of staged equipment. Consider an F29 powered by battery with a generator set connected to the alarm relays contacts and the output of the generator connected to a pump via the F29’s pump control relay (Relay 1).
- Page 27 and run-on timers previously described. To access the advanced functions press (^) followed by (P). If you do not require advanced functions press (P). You are then presented with a screen asking you to accept the current settings and exit the menu and run the pump. PRE-START DELAY TIMER The pre-start delay timer delays the starting of the pump each time the F29 is powered up.
- Page 28 The running of the batch can be initiated by powering up the F29 or by pressing the (R) button. The batch run can also be initiated by the closing of the contacts of a remote switch connected to the F29’s remote input.
- Page 29 If, however, there has been no draw-off from the tank during the 12 hour period, the automatic restart at the end of the delay will start the pump and run it for whatever period you have set on the start timer. The F29 will sense no flow because the float valve will still be closed.
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Page 30: Auto Restart
AUTO RESTART If the F29 is used in conjunction with an external pressure switch that is connected to its remote input it will be able to detect if the pump has run dry as a combination of no flow and low or no line pressure. If the pump does run dry the auto restart function can be set to automatically restart pump after a settable time. - Page 31 MAXIMUM STARTS PER HOUR The anti-cycling option built into the F29 allows the user to set the maximum number of times the pump can be safely started in any one hour period. If you select yes to this option the screen that follows will ask you to enter the maximum number of times the pump can be started in any one hour.
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Page 32: Leak Detector
BURST PIPE DETECTOR Note: The burst pipe detector requires an external pressure switch connected to the F29’s remote input to detect loss of pressure. It is commonly used in pressure systems to detect excessive run time due to a burst pipe. If a pressure system bursts its discharge pipe the pressure will fall and the pump will start when the external pressure switch closes. -
Page 33: Running Time Display
the time the leak detector was zeroed. If the leak detector screen displays no starts and no run time, then no leak has occurred from the system in the interim period. If the screen displays a number of starts and a total run time, a leak has occurred and the magnitude of the leak can be assessed by considering the total run time displayed and the capacity of the specific pump. -
Page 34: Maintenance
time displayed on the hour meter represents the actual hours the pump has run for in total. To reset the hour meter to zero, press the (v) button. To exit out of the hour meter screen press (P). The hour meter accumulates running time and does not lose its memory of the total pumping hours even if the power is switched off for extended periods. - Page 35 Products. Kelco does NOT warrant the Fitness of Kelco Products in a Customer Application. (3) You will confirm that Kelco Products are properly wired and installed for their intended use in your overall system. In the case of Kelco pump controllers, the flexibility of their operating system means it requires an extensive knowledge of pumps and their characteristics and the intended overall goal of the system in order to select the correct functions and settings.
- Page 36 PLEASE NOTE: Kelco Engineering Pty Ltd reserves the right to change the specification of this product without notice. Users will use their own judgment to determine the appropriateness of using Kelco Products in an application, any safety measures required and that the product is properly installed for that application .