KELCO F29 MK3 Assembly instructions

KELCO F29 MK3
INSTALLATION &
PROGRAMMING MANUAL
DIGITAL PUMP CONTROLLER
Engineering Pty Ltd
Sydney Australia
www.kelco.com.au
KELCO

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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. Installation must always be
carried out by a qualified pump engineer and all electrical work associated
with this controller must be carried out by a licensed Electrician. This
industrial control device must not be operated by persons (including
children) with reduced physical or mental capabilities, or lack of experience
and knowledge, unless they have been given supervision or instruction
concerning the use of this pump controller by a person responsible for their
safety.
VERY IMPORTANT SAFETY NOTICE
PLEASE READ THIS BEFORE INSTALLING THIS CONTROLLER

The F29 is controlled and configured using 4 onboard buttons.
(R) Reset button: Stops the pump and restarts the F29 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.
The F29 includes 4 multicolour lights to indicate activity.
Flow: This light is GREEN when the F29 detects flow and RED when no
flow is detected.
Pump: This light is GREEN when a pump is running and RED when the
pump is stopped.
Timer: This light may be GREEN or RED when a timer or special function
is running.
Remote: This light is BLUE when remote input No. 1 is closed and off
when the remote is open. The light is RED when remote input No. 2 is
closed and off when the remote is open. This light is PURPLE when both
remote inputs 1 & 2 are closed.
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. On start up the F29 will run the pump using its start up timer for
up to 5 seconds. If it finds flow in the first 5 seconds it will continue to run
the pump. If flow is lost, the pump will continue to run for 5 seconds held on
by the F29’s built in run-on timer. If flow fails to return, the pump will be shut
down after the run-on period. Pressing and releasing the (R) reset button on
the F29 or resetting the power will repeat this basic process.
THE LIGHTS
THE BUTTONS
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.
IMPORTANT: READ THIS FIRST
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1) Do not install the F29 in an exposed outdoor location. The F29 is
weatherproof, however, to ensure a long reliable life we recommend it be
protected from direct exposure to the sun and rain. A skull cap is provided with
the F29 and we recommend it be used to protect the F29 when direct
observation of the LCD screen is not required.
2 ) Do not expose the F29-S to freezing. If the F29 is to be used in areas
where freezing conditions will be encountered, use the stainless steel F29-
SS and always lag the pipework for several metres either side of the flow
switch to prevent the adjacent pipework from freezing.
3) Do not use the standard thermoplastic F29-S flow switch in hot
water applications. The standard F29-S is not designed to be used in
water hotter than 60ºC. The stainless steel model can be used in water up
to 90ºC.
When the F29 is powered up, pressing the (P) button, holding it down
for 1 second and releasing it takes you to the top of the menu. Pressing
and releasing the (P) button loads whatever the screen is displaying
into the F29’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. There is no need to step all the way through
the menu when making a change to a setting.
INSTALLING THE F29
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. The light can be
left permanently on or off as required.
The F29 monitors its internal temperature when running. Pressing the (v)
button while the flow switch is powered up displays the current internal
temperature of the F29.
TEMPERATURE
LCD SCREEN BACKLIGHT
PRESS (and release) THE (P) BUTTON
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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.
Where possible install the F29 in a location that is sheltered from direct
exposure to the weather. The F29 is weatherproof and is supplied with a
protective cover. However, to ensure a long reliable life we recommend it
be protected from direct exposure to the sun and rain. Intense sun light
will eventually cause discolouration and degradation of the flow switch’s
housing. It is therefore advisable to protect the F29 from the weather if
possible.
LOCATION
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The 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. It is more common to install it in the discharge pipe, either before or
after the system’s air cell. If the system includes an air cell a decision must
be made as to which side of the air cell to locate the flow switch. The way
the overall system functions will depend on this decision.
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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.
The only change in state the flow switch will see will be the closing of the
external pressure switch’s contacts on a falling pressure. Choose this
arrangement if you want to keep pump starts to a minimum and you are
prepared to accept the delay in starting associated with the slow pressure
fall from the air cell.
BEFORE THE AIR CELL
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Controller
Controller installed before the air cell
Discharge

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. Choose this arrangement if you want the
system to deliver a steady pressure and to start each time flow is sensed.
AFTER THE AIR CELL
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Controller installed after the air cell
Discharge
Controller

The F29 is supplied as two separate assemblies, the paddle assembly
and the electrical housing. The paddle assembly should be installed in
the pipework first.
The paddle of the F29 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. If a low flow rate is expected through the system the paddle
should be cut longer, perhaps until it only clears the bottom of the pipe by
3 to 5mm. If you are unsure as to what length the paddle should be, a
paddle trimming calculator is available at:
https://https://www.kelco.com.au/paddle-trimming-calculator/
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.
INSTALLATION
TRIMMING THE PADDLE
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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. a
Pressure Relief Valve (PRV).
To fit the paddle assembly into the pipework, apply Teflon tape or thread
sealing compound to the thread and use a suitable spanner and the
spanner flats provided on the paddle assembly (directly above the process
connection thread). Under no circumstances should the electrical housing
be twisted or used to screw the paddle assembly into the pipework or to
align the F29 with the axis of the pipework. To do so will irreparably
damage the F29 and void its warranty.
When correctly installed there should be a minimum 4mm gap between the
top of the pipe socket and the top of the thread on the F29. The F29 can be
installed in either vertical or horizontal pipe. The F29 has a 1” BSP process
FITTING THE PADDLE ASSEMBLY
VERY IMPORTANT SAFETY NOTE
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