Related Manuals for KELCO E30 Mk2
Summary of Contents for KELCO E30 Mk2
- Page 1 KELCO E30 Mk2 DIGITAL PRESSURE SWITCH INSTALLATION & PROGRAMMING MANUAL Version 090119 KELCO Engineering Pty Ltd Sydney Australia www.kelco.com.au...
- Page 2 VERY IMPORTANT SAFETY NOTICE PLEASE READ THIS BEFORE INSTALLING THIS CONTROLLER The E30 Mk2 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.
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Page 3: Important: Read This First
E30 and will void your product warranty. This E30 Mk2 digital pressure switch has been fully tested and calibrated. It is set to use kPa in mode 1 and it has its start-up and run-on timers both set to 5 seconds. -
Page 4: Lcd Screen Backlight
There is no need to step all the way through the menu when making a change to a setting. INSTALLING THE E30 Mk2 1) Do not install the E30 in a fully exposed outdoor location. The E30 is weatherproof, however, to ensure a long reliable life, we recommend it be protected from direct exposure to the sun and rain. - Page 5 4) Never expose the E30 to static or dynamic pressures greater than 20 Bars, 290 psi. 5) Do not install the E30 in a section of pipe that is subject to vibration. Vibration will cause premature failure of the electronic components within the controller.
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Page 6: Dynamic Pressure
DYNAMIC PRESSURE Consider the sections of pipe depicted in the sketch below. In sketch (A) the pressure as read by the E30 when water flows will be less than the pressure read by the pressure gauge. The difference between the two readings will be directly related to the flow velocity and the ratio of the two pipe diameters. -
Page 7: Installation
INSTALLATION The E30 consists of two separate parts, the process connection and the electrical housing. The two parts are locked together by an Allen screw located under the electrical housing. As supplied, the two parts are separate allowing the process connector to be screwed onto pipework using a suitable 1/4”... - Page 8 Locking Screw Process connector screwed onto a 1/4 BSP nipple in turn screwed into a pipe tapping point O-Ring seal must be in place, clean and in good order 1/4 BSP Nipple (Not included)
- Page 9 E30 MOUNTED DIRECTLY ON A PIPE ATTACHING THE ELECTRICAL HOUSING Once the process connector has been installed, fit the electrical housing onto the spigot on top of the process connector. Take care that the sealing O-ring on the top stem of the assembly is in location and in good order. There is a flat keying face on the cylindrical body of the process assembly that keys the electrical housing onto the process assembly and aligns it correctly.
- Page 10 DETACHING THE ELECTRICAL HOUSING Always switch off the power and de-pressurise the pipe WARNING: system before attempting to remove the electrical housing. To allow easy removal of the E30 from the pipework, the electrical housing can be detached from the process adaptor. Removing the electrical housing allows access to the process adaptor without the need to disconnect wiring.
- Page 11 TYPICAL WALL MOUNTED E30 Mk2 The single locking bolt secures the E30 to the wall Bracket Screw a 1/4 BSP 90 Degree elbow (not supplied) into the process port on the E30. The inlet port on the elbow must be alligned downward to...
- Page 12 1/4" BSP Process connection Female Removable cap Removable wall mounting Bracket 3 X M20x1.5 CAble Glands 137 mm 74 mm 4 x 6mm Holes WALL BRACKET DRILL PATTERN...
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Page 13: Electrical Installation
ELECTRICAL INSTALLATION WARNING All electrical work associated with the E30 must be carried out by qualified electrical personnel and all electrical work must conform to AS/NZ standards and to local wiring rules. INTRODUCTION When used with its HD terminal link in place the E30 can directly control single-phase motors to 2.4kW via its Relay 1. - Page 14 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.
- Page 15 E30’s reset button. CABLES The E30 Mk2 has 3 X M20 cable glands. The cable glands can accept cable from 7 to 9mm diameter. See sketch for assembling the cable gland components. The controller is supplied with a set of steel crimp rings. The crimp rings are to provide strain relief for the controller’s cables.
- Page 16 18VAC 50Hz or 18VDC RELAYS The E30 Mk2 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.
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Page 17: Remote Inputs
E30 is powered from the mains. Relative to earth, the LV terminal is at full mains potential. The E30 Mk2 has two remote inputs.marked RMT1 and RMT2. Remote... - Page 18 input 1 can be configured to operate in various ways in the program such as start and stop for connection to tank level switches or for connection to a remote flow switch in dual pump mode. Remote input 2 has a fixed function, it replicates the main reset button on the E30.
- Page 19 EXAMPLE A water tank is located 2000 metres from the E30. 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 E30 (with the tank level switch closed) is 382 Ohms.
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Page 20: Wiring Diagrams
WIRING DIAGRAMS PLUG & PLAY CONNECTIONS 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 21 DUAL SINGLE PHASE PUMPS & 2 REMOTE INPUTS CONTROL OF A SINGLE PHASE PUMP MOTOR WITH A SECONDARY BACK UP PUMP AND TWO REMOTE INPUT SWITCHES Supply 110 ~ 240VAC 50/60Hz. This link wire must be used whenever the controller is directly controlling a single Active phase pump motor, as shown.
- Page 22 BASIC 3 PHASE PUMP CONTROL BASIC THREE PHASE PUMP CONTROL Contactor WARNING Contactor coil rating must not exceed 240VAC 3 Phase Pump Motor 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...
- Page 23 3 PHASE CONTROL WITH ALARM & REMOTE INPUT THREE PHASE PUMP CONTROL WITH ALARM AND REMOTE INPUT Remote switch with NO or NC voltage free contacts Alarm 16A 240V Maximum resistive load Contactor WARNING Contactor coil rating must not exceed 240VAC Three Phase Pump Motor...
- Page 24 THE 12VDC E30 DIGITAL PRESSURE SWITCH A low voltage DC version of the E30 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 25 Doing this removes any settings you may have entered and restores the E30 to its default state. LOCKING & UNLOCKING THE E30 Mk2 The E30 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 26: Getting Started
USE REMOTE 2 FOR REBOOTING Lets you use a remote normally open switch to remotely reboot the E30 Mk2. Press and release (P) again. SELECT PRESSURE UNITS: kPa. Press and release the (˅) button to change kPa to psi. - Page 27 SELECTING A SUITABLE OPERATING MODE Selecting a suitable operating mode is critical to the use of the E30. The mode you choose will depend on exactly what the pump system is required to do and how you want it controlled. Step through the modes by pressing the (˅) (˄) buttons.
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Page 28: Optional Functions
sets, dual alternating pump sets and line pressurising systems. OPTIONAL FUNCTIONS Each mode includes optional functions enabling the E30 to be configured to a specific application. A detailed description of the functions follows. Some options are mode specific. The relevant modes for each function are indicated by number in the functions heading. - Page 29 because of over pressure. Relay 2 is closed if the E30 CLOSED ONLY ON A LO PRESS FAULT stops because of under pressure. When using the batching CLOSED ONLY WHEN BATCH COMPLETE function, relay closes when the batch is complete. If you select the anti-cycling STARTS PER HOUR SETTING EXCEEDED feature from the menu and the pump shuts down because the number of...
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Page 30: Delayed Restart
pressure is detected. The start-up timer is factory set to 5 seconds. It can be set between 1 second and 900 seconds using the (˅) and (˄) buttons. RUN-ON TIMER Modes 1 2 The E30 includes a run-on timer that can be set from 1 second to 900 seconds in increments of 1 second. - Page 31 AUTO RESTART IF RUN DRY Mode 1 The E30 will identify a dry run situation as a loss of pressure. 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.
- Page 32 START PRESSURE Mode 1 The start pressure can be set to any value from 1 kPa to 2000 kPa or from 1 psi to 290 psi in increments of 1 kPa or 1 psi. Normally the start pressure will be set to the pressure at which you want the pump to start. In normal operation, each time pressure drops to whatever value you have set, the pump will start.
- Page 33 Take great care in using the high pressure run-on and its associated settings. Always set the high pressure limit to a pressure that is well below the pumps shut off head. Keep the high pressure run-on time to a minimum to avoid overheating the pump due to recirculation. HIGH PRESSURE RUN-ON (Time) If you previously set high pressure run-on to YES (ON), the question that follows asks you to set a run-on time.
- Page 34 ANTI-CYCLING Mode 1 Electric motors are often limited in the number of times they can be safely started in any one hour. This is particularly important in the operation of submersible bore pumps. When a motor starts there is an initial inrush of current that produces heat in the coils and iron rotor of the motor.
- Page 35 LOW-PRESSURE TRIP Mode 2 The low-pressure trip point can be set to any value from zero to 2000 kPa or from zero to 290 psi. The low-pressure trip point must be set to some value that is less than the high-pressure trip point. If you attempt to set the low-pressure trip point to a pressure that is greater than the high-pressure trip point you will invoke a warning from the E30 alerting you to the problem.
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Page 36: Set Pressure
range that is limited to 2000 kPa or 290 psi. If the system pressure exceeds this limit for any reason and reaches 2200 kPa or 430 psi the E30 will automatically shut down the system and display a message that its 22 Bar excess pressure limit has been exceeded. - Page 37 time. It also displays a countdown “Alt xxx” in the bottom right corner of the screen indicating a countdown of the pump alternations. The count starts at whatever number was entered for alternations and reduces by one each time the pump stops. When the count reaches zero the second pump starts.
- Page 38 SET THE PRESSURE PUMP 1 Mode 4 The E30 menu asks you to set the required operating pressures for each pump starting with pump one. Pump one will be the pump controlled by relay 1 in the E30. The pressures you set will depend on the application. Generally, pump one should be considered the main pump.
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Page 39: Maintenance
WARRANTY The E30 Mk2 is warranted against faulty workmanship and materials for a period of 12 months from the date of purchase. Our complete warranty statement can be downloaded from: - http://www.kelco.com.au/menu/information/warranty-statement... - Page 40 This Warranty and Limitation of Liability (or any more recent version in effect when you purchase a Kelco Product) (“Warranty”) applies to all Kelco Products regardless of where you purchased the Kelco Products.
- Page 41 (4) When using Kelco Products, you will make sure to (i) maintain a margin of safety in relation to the published rated and performance values, (ii) design to minimize risks to any Customer Application in case of failure of any Kelco Products, such as introducing redundancy i.e.
- Page 42 Products by the customer. . (2) Sole Remedy: Unless required to do otherwise as a result of statutory guarantees applicable under ACL, Kelco will provide, at its own discretion, either of the following two services as the sole remedy for a malfunctioning Kelco Product:...
- Page 43 (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;...
- Page 44 LIABLE FOR ANY DAMAGES WHICH MAY ARISE FROM OR BE RELATED TO KELCO PRODUCTS. 7. Confidentiality: You accept that if you make a Warranty claim, Kelco and its agents may exchange information in relation to you to enable Kelco to meet its obligations under this Warranty.
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