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KELCO IPG20 MK3 Installation & Programming Manual

Intelligent pump guard
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KELCO IPG20 MK3
INTELLIGENT PUMP GUARD
INSTALLATION &
PROGRAMMING MANUAL
KELCO
Engineering Pty Ltd
Sydney Australia
www.kelco.com.au

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  • Page 1 KELCO IPG20 MK3 INTELLIGENT PUMP GUARD 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 IPG20 MK3 is an industrial control device. It is specifically designed for use in dairy and agricultural 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.

  • Page 3: Important: Read This First

    IPG20 and will void your product warranty. OVERVIEW The IPG20 MK3 intelligent pump guard is a pressure and flow based device that “learns” the operating pressure each time the system is started. This allows for finely targeted parametres where any significant variation in the operating pressure or loss of flow will trigger an alarm and shut the system down.

  • Page 4: Lcd Screen Backlight

    THE BUTTONS IPG20 is controlled and configured using 4 onboard buttons. (R) Reset button: Stops the pump and restarts the IPG20 when released. (^) Up arrow button: For increasing program settings. (v) Down arrow button: For decreasing program settings. (P) Programming button: For stepping through the menu and entering settings into memory.
  • Page 5 Pressing and releasing the (P) button loads whatever the screen is displaying into the IPG20’s memory. The memory is non-volatile and settings are retained when power is off. You can exit the menu at any time by pressing and releasing the (R) button. Any settings you have made up to that point will be retained.
  • Page 6 The IPG20 is weatherproof and can be used in fully exposed locations; however, to ensure a long reliable life from the controller we recommend it be protected from direct exposure to the sun and rain. Intense sunlight will eventually cause discoloration of the clear lid on the controller and will also degrade its LCD screen.

  • Page 7: Installation

    INSTALLATION The IPG20 pump guard is supplied as two separate assemblies, the paddle assembly and the electrical housing. The paddle assembly should be installed in the pipework first and the electrical housing should then be fitted onto the spigot on top of the paddle assembly, taking care that the sealing O-ring is on the stem and is in location and in good order.

  • Page 8: Important Safety Note

    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 9 Spare paddles and trailing wires to suit the IPG20 pump controller are available from Kelco or from your distributor. Apply sealing compound or Teflon tape to the process connection thread on the controller and screw the controller into the pipework using the spanner flats on the process connection.

  • Page 10: Sensitivity Adjustment

    Once the electrical housing has been removed, the paddle assembly can be unscrewed from the pipework using the spanner flats on the body of the paddle housing. Simply reverse this procedure to refit the electrical housing to the controller, taking care to ensure the O-ring on the top of the paddle assembly is in place and is clean and in good condition.

  • Page 11: Electrical Installation

    ELECTRICAL INSTALLATION WARNING All electrical work associated with the IPG20 must be carried out by qualified electrical personnel and all electrical work must conform to AS/NZ standards and to local wiring rules. IMPORTANT A means for disconnection of the IPG20 must be incorporated in the fixed wiring in accordance with the wiring rules.
  • Page 12 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 13 BROWNOUT OR BLACKOUT If a blackout or brownout occurs the IPG20 will not retain any memory of where in its run or stop cycle it may have been, it will simply shut down the pump. When power resumes, the IPG20 will attempt to reboot, restart the pump and run any timer settings from the beginning.
  • Page 14 25mA Max at 24VDC 0.60W RELAYS The IPG20 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. When operating the IPG20 as a dual pump controller, Relay 2 is used to control the second pump.

  • Page 15: Remote Inputs

    IMPORTANT: When directly controlling a pump motor through Relay 1, always link the HD terminal to Relay 1 Normally Open terminal and make sure the maximum switched motor current never exceeds 10 Amps. On a pump motor P1 must not exceed 2.4kW. REMOTE INPUTS WARNING: The low voltage source available at the LV terminal is non-...
  • Page 16 The total cable resistance must not exceed 5K Ohms with the remote switch closed. The total capacitance of the cable must not exceed 25nF with the remote switch open. Wires to the remote switch should be run separately from power carrying cables. Do not run the remote switch wires in a conduit that also contains power cables.

  • Page 17: Wiring Diagrams

    WIRING DIAGRAMS PLUG & PLAY CONNECTIONS 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 Supply 110 ~ 240VAC 50/60Hz. Active This link wire must be used whenever the controller is directly controlling a single Neutral...

  • Page 18: 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 Pump Motor 2 Single Phase 110 ~ 240VAC Motor 3A...
  • Page 19 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 20 3 PHASE PUMP WITH ALARM AND REMOTE SWITCH Remote switch with NO or NC voltage free contacts Alarm 16A 240V Maximum resistive load Contactor WARNING Contactor coil rating must not exceed 240VAC 3 Phase Pump Motor MP WITH 24V CONTROL CIRCUIT & SOLENOID VALVE Remote switch Solenoid Valve Transformer...
  • Page 21 3 PHASE PUMP WITH 240V CONTROL CIRCUIT & REMOTE 24V SOLENOID VALVE Remote switch 24VAC 240/24V 24VAC Solenoid TRANSFORMER Valve Contactor WARNING 3 Phase Pump Motor Contactor coil rating must not exceed 240VAC...
  • Page 22 12VDC IPG20 MK3 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 HD link 14 ~ 40VDC in 3 phase or single phase control circuit applications...
  • Page 23 If a remote switch is connected to the 12V DC IPG20 MK3 the supply to the remote switch must be taken from the positive terminal on the IPG20.
  • Page 24 PROGRAMMING THE IPG20 For a description of the functions of the buttons and lights, please read pages 2 and 3 of this manual before proceeding. RESTORING FACTORY DEFAULTS (Purging the Settings) You can restore the IPG20 to its default factory settings at any time by pressing and holding down the (P) button and pressing and then releasing the (R) button.
  • Page 25 2) When changing modes always start by purging the previous settings, to restore factory defaults, before proceeding. This ensures no conflicts occur between previously set functions and new functions. 3) Set realistic and sensible values into the various functions. For example, do not set a pump to stop at a lower pressure than it is set to start at.
  • Page 26 Flow, and any loss of pressure or flow outside the margins will trigger a shut down after the pre-set delays expire. The switch will then display the reason for the shutdown, and if configured, close the alarm relay to trigger an optional external alarm or dialler which can text to alert the operator of a problem.
  • Page 27 THE IPG20 FUNCTIONS (#Settable) # Manual or automatic operation # Auto terrain compensation (Travelling irrigator) # Drift allowance in kPa (Auto terrain compensation only) # Pre-start delay timer # Alarm relay (Configurable, eg. priming valve, alarm light, etc) # Absolute low limit (System pressure must always be above this) # Low pressure margin (Fine leak detection) # Absolute high pressure limit (Overpressure) # High pressure margin (Partial blockage)
  • Page 28 SUGGESTED FIRST SETTINGS WITH TRAVELLING IRRIGATOR AND AUTOMATIC STARTING These settings are suggestions to get started. All final settings are site specific and must be relevant to the installation. Function Suggested setting Displayed on screen Allows pressure change due to contour change Auto terrain compensation 10kPa...
  • Page 29 SUGGESTED FIRST SETTINGS WITH FIXED SPRINKLERS AND AUTOMATIC STARTING These settings are suggestions to get started. All final settings are site specific and must be relevant to the installation. Suggested setting Function Displayed on screen Auto terrain Not required for fixed pods compensation Fully Automatic Pump will be started after the 'start after' time...

  • Page 30: Manual Operation

    MANUAL OPERATION In manual operation the learning phase of the start-up process is instigated by the operator activating the remote switch once it is established the system is running as expected, and at a pressure which is appropriate for the particular outlet/hydrant setup.
  • Page 31 It is important that there are no leaks or other problems at this stage as they could be locked in by the switch as being normal. If the automatic mode is selected it is strongly recommended that a visual check of the system is done.
  • Page 32 By doing this the operator can differentiate between a setting which is too fine, from a trip from a genuine leak or blockage. As the set point pressure moves up or down with the terrain it is important to realise the sum of the operating pressure and the high or low margins cannot be greater or less than the overriding high or low set points.
  • Page 33 If you decide to use the alarm relay, it can be configured in the following ways: Closed if any fault develops If the pump is stopped on any fault condition the alarm relay will close its contacts. This can be used for an alarm light or, perhaps, a dialer to alert the operator of a problem.
  • Page 34 Closed on very low pressure fault The alarm relay will only close if a very low pressure is detected. Closed on very high pressure fault The alarm relay will only close if the pressure rises above the very high pressure setting. There is no time delay on this setting. Closed if ramp up timer times out The alarm relay will only close if the ramp up timer times out.
  • Page 35 ABSOLUTE LOW LIMIT This is an over-riding low pressure setting that gives overall protection against a major breach in the system that may have occurred between irrigation cycles. This would be set just below what would be the lowest operating pressure expected anywhere in the system. If the pressure drops below, or never achieves this setting, the IPG20 will shut down the system and display “pressure too low”.
  • Page 36 SET POINT MARGIN The set point will only be locked in if the switch measures six readings within the margin. This margin allows for some pressure variation as the pressure stabilises, eg. some air still being purged from the system. A setting of 20kPa is generally OK.
  • Page 37 SET POINT TIMER The set point timer is imbedded in the program and not available in the menu. There is a maximum of 300 seconds (5 minutes) available to obtain 6 readings which are taken 10 seconds apart. The set point timer is the time allowed for the set point to be measured and locked in once the system pressure has stabilised.
  • Page 38 PRESSURE SPIKE TIMER The time allowed before the pump is stopped if a high pressure is detected. This is over-ridden by the absolute high setting. If the pressure rises to the absolute high value it will stop the pump instantly. Once the set point is locked in the IPG20 enters normal running.
  • Page 39 For most applications an initial setting of a few seconds is quite adequate. The self-resetting action of the run-on timer means it will keep a pump running in spite of repeated or continuous interruptions to flow. In applications where entrained gas is present in the water, the run-on timer will ignore the continuous bouncing back and forward of the paddle by constantly resetting its time clock instant by instant.
  • Page 40 CYCLIC RUNNING The IPG20 can be programmed to run and stop a pump for set periods of time. Both the running and stopping times can be set to any value you choose, from 1 minute to 99 hours 59 minutes (0 to just over 4 days) in increments of 1 minute.

  • Page 41: Normal Running

    Total run time includes all peripheral times such as run-on and pressure dip time and the initial flow start and pressure start times. It also includes run time incurred during cyclic running. The run time display has a range of 1 minute to 9999 minutes (about 7 days).

  • Page 42: Maintenance

    If a warranty issue arises with this product contact your supplier or Kelco Engineering Pty Ltd. You will be issued with a returns goods authorisation number. The RGA number and proof of purchase must accompany any goods returned to us under warranty.
  • Page 43 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 44 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 .

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