Related Manuals for KELCO F60 MK3
Summary of Contents for KELCO F60 MK3
- Page 1 KELCO F60 MK3 DIGITAL PUMP CONTROLLER INSTALLATION & PROGRAMMING MANUAL KELCO Engineering Pty Ltd Sydney Australia www.kelco.com.au...
- Page 2 0 to 2000kPa, 0 to 20 Bars, 0 to 290 psi. It must never be exposed to static or dynamic pressures in excess of 20 bars, 290 psi. The F60 MK3 must never be exposed to negative pressure. Never install the F60 MK3 on the suction pipe work of a pump.
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Page 3: Important: Read This First
1 and it has its start-up and run-on timers both set to 5 seconds. All other functions are turned off. On start up the F60 MK3 will run the pump using its start-up timer. If it finds flow in the pipe system it will continue to run the pump. -
Page 4: Lcd Screen Backlight
If the F60 MK3 is to be used in areas where low temperatures will be encountered, always lag the pipework for several metres either side of the F60 MK3. Also lag the base of the F60 MK3 to prevent the unit and any adjacent pipework from freezing. - Page 5 4) Never expose the F60 MK3 to static or dynamic pressures greater than 20 Bars, 290 psi. 5) Do not install the F60 MK3 in a section of pipe that is subject to vibration. Vibration will cause premature failure of the electronic components within the F60 MK3.
- Page 6 LOCATION The F60 MK3 should be installed in a straight section of pipe preferably with 5 diameters of straight pipe either side of the paddle. The F60 MK3 can be installed in a suitable pipe socket, tapping saddle or pipe tee. The F60 MK3 should be installed in the discharge pipework of the pumping system, either before or after the system’s air cell.
- Page 7 BEFORE THE AIR CELL If the F60 MK3 is installed before the air cell in the system it will only start the pump on pressure since the initial flow will be supplied from the air cell. The only change in state the controller will see will be the falling pressure.
- Page 8 AFTER THE AIR CELL If you install the F60 MK3 in the pipework after the air cell it will start the pump each time flow pushes its paddle forward or each time pressure falls to whatever pressure you have set the controller to start at. Choose this arrangement if you want the system to deliver a steady pressure and to start each time flow is sensed.
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Page 9: Installation
INSTALLATION The F60 MK3 pump controller is supplied as two separate assemblies, the paddle assembly and the electrical housing. The paddle assembly should be installed in the pipework first. - 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 TRIMMING THE PADDLE The paddle of the F60 MK3 can be cut down to suit the specific pipe size and intended application. Cut the paddle using a hacksaw or tin snips so it clears the sides of the pipe socket and protrudes approximately half to two thirds of the way across the pipe when the controller is screwed into the pipework.
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Page 12: Detaching The Electrical Housing
SENSITIVITY ADJUSTMENT Under the end of the electrical housing on the F60 MK3 is a red hexagonal dust cap. If you remove this dust cap you gain access to an adjustment screw that allows the paddle preload to be reduced. - Page 13 A far better arrangement is to monitor flow from each pump independently. To give each pump individual loss of flow protection the F60 MK3 should be installed in the discharge pipe of one pump and a basic flow switch installed in the discharge pipe of the second pump.
- Page 14 The remote flow switch can be a paddle switch, as illustrated, or an in line flow switch. It must have normally open voltage free contacts. Kelco F Series Flow Switch...
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Page 15: Electrical Installation
2.4kW via Relay 1 normally open contacts. No interposing contactor is required for such applications. The F60 MK3 can also be used to control 3 phase pump motors of any size via an appropriate interposing contactor. -
Page 16: The Hd (Heavy Duty) Terminal
The HD terminal should not be used when the F60 MK3 is connected to a contactor, external timer, low wattage relay or to any other external device where voltage free contacts are required. -
Page 17: Brownout Or Blackout
7 to 9mm diameter. See sketch below for assembling the cable gland components. The F60 MK3 is supplied with a set of steel crimp rings. The crimp rings are to provide strain relief for the controller’s cables. To use the crimps, place one on the cable approximately 3 to 4mm below the end of the cables outer sheathing. - Page 18 110VAC 50Hz RELAYS The F60 MK3 houses 2 relays. Relay 1 has S.P.D.T contacts. Relay 2 has S.P.S.T Normally Open contacts. Relay 1 is normally regarded as the pump control relay and relay 2 is normally regarded as the alarm relay.
- Page 19 We suggest a maximum C10 Amp breaker be used for the supply isolation. The power required to drive the F60 MK3 depends on the supply, AC or DC and on temperature. The table below gives the maximum power required from various supplies at 25°C.
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Page 20: Remote Inputs
An external switch with voltage free contacts such as a tank level switch or a set of external relay contacts can be used to control the F60 MK3. The supply to the external switch must be taken from the LV terminal on the F60 MK3 when the controller is powered from the mains or from a 24VAC source. - Page 21 Capacitive coupling between the adjacent cables may cause false triggering of the F60 MK3’s remote inputs. For cable runs longer than 150 metres we suggest using 2 separate wires to reduce capacitive coupling between the adjacent wires. When set up this way cable resistance becomes the limiting factor for distance.
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Page 22: Wiring Diagrams
WIRING DIAGRAMS PLUG AND LEAD WIRING Optional voltage free external input All electrical wiring associated with this controller must be carried our by a qualified electrician Earth Link CONNECTIONS FOR A SINGLE PHASE PUMP Control of a Single Phase Pump with an Alarm and two remote inputs Supply 110 ~ 240VAC 50/60Hz. - Page 23 LOW VOLTAGE SUPPLY Supply 18 to 24 Volts AC or DC Negative Positive BASIC 3 PHASE PUMP CONTROL BASIC THREE PHASE PUMP CONTROL Contactor WARNING Contactor coil rating must not exceed 240VAC 3 Phase Pump Motor...
- Page 24 DUAL 3 PHASE PUMP CONTROL 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 DUAL 3 PHASE PUMP CONTROL Contactor 1 3 Phase Pump Motor 1 Contactor 2 WARNING 3 Phase Pump Motor 2...
- Page 25 1. The remote flow switch would normally be installed in the discharge pipe of pump 2. The remote flow switch can be a paddle style switch such as the Kelco F Series as depicted or an in line style flow switch such as a Kelco C25-B.
- Page 26 3 Phase Pump Motor THE 12VDC F60 MK3-12 PUMP CONTROLLER A low voltage DC version of the F60 MK3 is available for battery operation and for use in solar pumping systems. Functionally the F60 MK3-12 model is the same as the mains voltage model except for the terminal block markings.
- Page 27 12VDC F60 MK3-12 CONTROLLING A SINGLE PHASE PUMP 12VDC Controlling a Single Phase Pump This link wire must be used whenever the controller is directly controlling a single Alternate Positive phase pump motor, as shown. Do NOT use the 14 ~ 40VDC...
- Page 28 LOCKING & UNLOCKING THE F60 MK3 The F60 MK3 is supplied by the factory in an unlocked state and can be programmed using its buttons. To prevent unauthorised personnel from altering its settings, the programming button (P) can be locked.
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Page 29: Getting Started
Step through the modes by pressing the (˅) and (˄) buttons. Highlight the mode you want to use and press and release (P) to lock it into the F60 MK3’s memory and to advance to the next screen. - Page 30 F60 MK3, thereafter the pump is run within these pressure limits. If the pump runs dry it will be shut down based on a combination of loss of flow and a low pressure.
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Page 31: Optional Functions
Modes 1 2 3 4 5 A remote switch with voltage free Normally Open contacts can be connected to the remote input terminals No. 1 on the F60 MK3 and configured in various ways. Use the (˅) and (˄) buttons to highlight a suitable selection. - Page 32 No. 2, RMT2. Closing this switch causes the F60 MK3 to stop whatever it is doing and reboot. In effect it acts in the same way as pressing the red Reset button on the F60 MK3. If the remote...
- Page 33 START-UP TIMER Modes 1 2 3 4 5 The start-up timer operates when the F60 MK3 is first turned on. Its purpose is to ignore any initial lack of flow and to allow time for the pump to start and for flow to be detected. The timer is auto self-terminating and terminates its run as soon as flow is detected.
- Page 34 In mode 4 the pressure timer is a single shot timer that only runs once each time the F60 MK3 boots up and starts the pump. Its purpose is to allow time for the system pressure to rise to above whatever low pressure trip point you may have set.
- Page 35 If the stop time is left set at zero, the F60 MK3 will behave as a one-shot batch controller. On pressing the reset button or switching the pump on, the pump will run for the set period and then shut down.
- Page 36 (starting and stopping). MAXIMUM STARTS PER HOUR The anti-cycling option built into the F60 MK3 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 using anti-cycling the screen that follows will ask you to enter the maximum number of times the pump can be started in any one hour.
- Page 37 LOW PRESSURE DETECTED. The pump will continue to run and the F60 MK3 will monitor the pressure. If the pressure rises to above the low trip pressure setting, the controller will return to normal operation.
- Page 38 If the pressure remains below the low trip pressure point when the trip pressure timer times out, the pump will be shut down and the F60 MK3 screen will display PRESSURE TOO LOW. LOW PRESSURE TRIP Mode 4 Mode 4 asks you to enter a low trip pressure. The low trip pressure is the lowest pressure you want the system to operate at.
- Page 39 The stopping pressure must be set higher than the starting pressure and the starting pressure must be set higher than the low trip pressure (if used). Failure to set the pressures correctly generates an on- screen error message. HIGH PRESSURE RUN-ON Mode 3 If you set high pressure run-on to “YES”...
- Page 40 On a rising pressure the F60 MK3 will start the high pressure run-on timer as soon as it detects pressure higher than the normal stop pressure. The high pressure run-on timer will run for whatever you set it to and expect pressure to fall back below the normal stop pressure before it times out.
- Page 41 ALTERNATE THE PUMPS EVERY 000 STARTS and (˄) buttons to set the required alternation frequency. When running, the F60 MK3 displays which of the 2 pumps is running and counts down the alternations. SET THE PRESSURE PUMP ONE Mode 5 In mode 5, set the starting and stopping pressure for pump 1.
- Page 42 In mode 5 flow detection can be applied to the pumps individually or to both pumps or it can be left turned off. This function allows the F60 MK3 to be installed at various locations in the dual pipe system and to monitor flow at the specific location or in 2 locations simultaneously.
- Page 43 AUTO RESTART IF RUN DRY Modes 2 3 4 The F60 MK3 will identify a dry run situation as a loss of both pressure and flow. If the pump shuts down because it has run dry, it can be set to try to restart using the auto restart function after a settable delay.
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Page 44: Leak Detector
If you accept yes and press (P), you are then asked to press the reset button to start the pump. The F60 MK3 will start the pump and attempt to run the system using the settings you have programmed in. If the settings... -
Page 45: Spare Parts
. To the extent permitted by law Kelco Engineering Pty Ltd disclaims and excludes all and any liability for the use of this product in any particular... - Page 46 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 47 (4) If you intend to make a claim under this Warranty you must contact Kelco to register your claim by telephone on (02)99056425 and provide the following details to enable Kelco to assess the claim: (i) proof of purchase; (ii) evidence of the particulars of the claim that gives rise to the application of the Warranty ;...
- Page 51 5. Non-excludable Statutory Guarantees (1) The Warranty is given by Kelco in addition to other rights and remedies which you may be entitled to under by law, nothing contained in this agreement excludes, restricts or modifies any condition, guarantee, warranty or other obligation which is applicable to or is conferred on Kelco pursuant to law where to exclude, restrict or modify any such condition, warranty or other obligation is unlawful.