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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connection. A matching female threaded socket, pipe saddle or pipe tee
must be provided to fit the F29 into the pipework.
Under the end of the electrical housing on the F29 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. As supplied the sensitivity
adjustment screw is wound fully in. In this position the paddle is at its least
sensitive. In this position it takes a substantial force from the moving water to
move the paddle. If you take a straight bladed screwdriver and wind the
sensitivity adjustment screw anti-clockwise (outward) the force against the
paddle that resists flow will be reduced.
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. It is critical that the keying flat is on the downstream side and at
90 degrees to the axis of the pipework (see sketch). To secure the
electrical housing onto the paddle assembly an Allen head cap screw is
supplied. The cap screw should be screwed fully through the hole provided
on the underside of the electrical housing and should be securely tightened
using a 3mm A/F Allen key (supplied).
To allow easy access to the flow switch’s paddle, the electrical housing of
the F29 can be detached from the paddle assembly. Removing the electrical
housing allows access to the paddle without the need to disconnect the
electrical connections to the F29. To remove the electrical assembly, switch
off the system’s power and undo and completely remove the locking screw
(see diagram). Once the locking screw is removed, lift the electrical housing
straight off (do not twist it when doing this). 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 assembly. Simply reverse this
procedure to refit the electrical housing to the F29.
SENSITIVITY ADJUSTMENT
ATTACHING THE ELECTRICAL HOUSING
DETACHING THE ELECTRICAL HOUSING
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When used with its HD terminal link in place, the F29 can directly control
single-phase pump motors to 2.4kW via its relay 1. No interposing
contactor is required for such applications. The F29 can also be used to
control 3 phase pump motors of any size via an appropriate interposing
contactor.
The F29 requires a stable 220V to 240V AC supply when operated from
the mains. It can also be operated from an 18 to 24V AC or DC supply by
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.
The range of sensitivity adjustment will also be affected by the orientation of
the F29. In horizontal pipework with the F29 mounted vertically the useable
range of adjustment is approximately 8 turns. In vertical pipe with flow
upwards, the full 10 turn range can be utilised.
WARNING
All electrical work associated with the F29 must be carried
out by qualified electrical personnel and all electrical work
must conform to AS/NZ standards and to local wiring rules.
WARNING: The contactor control circuit must never exceed 240VAC.
Never series connect the F29 relay contacts and contactor coil directly
across 2 phases
INTRODUCTION
ELECTRICAL INSTALLATION
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To use the HD drive, place a heavy link wire between the HD terminal and
the Normally Open terminal of Relay 1.
The F29 contains a solid-state switch (HD Heavy Duty drive) that can be
used to protect the contacts of Relay 1 by eliminating the destructive
arcing caused by the starting and stopping of pump motors. The solid-
state switch is accessible from the HD terminal on the terminal block. We
recommend the HD drive be used whenever the controller is used to
directly control a single-phase pump motor. The HD drive should not be
used when the F29 is connected to a contactor, external timer, low
wattage relay or to any other external device where voltage free contacts
are required. It is strictly intended for the direct control of highly inductive
AC motor loads. The HD terminal and the controller’s built in relays must
never be directly connected to a DC motor under any circumstances.
When the HD terminal is linked to the normally open terminal of Relay 1,
the HD drive in effect parallels a 42 Amp solid state switch across the
relay’s normally open contacts. This increases the momentary current
carrying capacity of the relay’s contacts to well over 60 Amps. The
solid- state HD drive is only activated for a brief period when the pump
starts and stops. It effectively handles the high inrush current associated
with the pump starting, and it provides a current path for the destructive
back EMF associated with the pump motor stopping.
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. This is particularly important where long cable runs are to be used in
the installation. If the voltage drop associated with the starting of the pump
motor is excessive the F29 may repeatedly reset and not operate properly.
THE HD (Heavy Duty) TERMINAL
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A means for disconnection of the F29 must be incorporated in the fixed
wiring in accordance with the wiring rules.
If a blackout or brownout occurs the F29 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 F29 will reboot, restart the pump
and run any timer settings from the beginning. A manual reboot can be
done at any time by pressing and releasing the F29’s reset button.
The F29 has 3 X M20 cable glands. As supplied, the cable glands are
blanked off with rubber plugs. To use the glands first remove one of the
rubber plugs and assemble the (supplied) cable gland bush and backing
washer into the cable port. The cable glands can accept cable from 7 to
9mm diameter. See sketch for assembling the cable gland components.
The F29 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. Crimp the two ears of the ring flat using bull nosed pliers. Pull
the cable back through the cable gland until the crimp ring’s ears are fully
located into the slots in the cable gland housing. Always leave unused
cable glands sealed off using the (supplied) rubber plugs.
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.
CABLES
IMPORTANT
BROWNOUT OR BLACKOUT
WARNING
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Maximum Supply Voltage
Minimum Supply Voltage
Maximum Supply Voltage
Minimum Supply Voltage
260VAC
190VAC
25VAC or 25VDC
18VAC or 18VDC
The power required to drive the F29 depends on the nature of the supply,
AC or DC and on temperature. The table below gives the maximum power
required from various supplies at 25°C. As temperature increases, the
power required will reduce. For example, at 30°C the power requirement
will be approximately 3% less than the values given in the table. The
measurements expressed in the table represent the maximum required
power with both relays 1 and 2 closed and the LCD backlight and all
indicator lights on.
VOLTAGE LIMITS ON TERMINALS A & N
ELECTRICAL LIMITS
VOLTAGE LIMITS ON TERMINALS LV & N
4mm
Rubber Plug
M20 Gland Nut
Backing Washer
Plug unused cable
glands using the
rubber plugs
(supplied). Fully
tighten the gland nut to
seal the unused cable
port.
Rubber Grommet
Controller Housing
Backing Washer
Cable 7mm to 9mm diameter
Crimp the ears of the
strain relief ring onto
the cable and pull the
cable back into the
slots in the gland
housing.
POWERING THE F29
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RELAYS
MAXIMUM PUMP MOTOR LOAD FOR RELAY 1
POWER REQUIRED TO DRIVE THE 12VDC F29-12
POWER REQUIRED TO DRIVE THE STANDARD F29
10A at 240VAC 2.4kW
24VDC Supply to LV & N
24VAC 50Hz Supply to LV & N
220VAC 50Hz Supply to A & N
240VAC 50Hz Supply to A & N
Inductive Motor Load
Maximum 68mA 1.63Watts
Maximum 108mA 2.34Watts
Maximum 87mA 2.00Watts
Maximum 94mA 2.54Watts
With Both Relays Closed 68mA Max at 12VDC 0.81W
With One Relay Closed 52mA Max at 12VDC 0.62W
Quiescent State (relays open) 25mA Max at 12VDC 0.30W
The F29 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.
With the HD terminal linked to the NO terminal of Relay 1, the F29 can
directly control a single phase motor up to 2.4kW via its NO contacts.
Without the HD terminal link in place, relays 1 & 2 are limited to directly
controlling a motor to 0.75kW. Both relays can control motors of any
required size via interposing contactors.
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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.

The remote switch can be installed some distance from the F29. The
maximum distance is limited by cable resistance and capacitance. 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. Capacitive coupling between the adjacent
cables may cause false triggering of the F29’s remote input. 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. The table below
sets out the resistance of typical copper wire of various diameters.
Note that the cable resistance refers to the total resistance out to the
remote switch and back, as measured at the controller across the 2 remote
connection wires with the external remote switch closed.
A mains voltage rated external switch with voltage free contacts such as a
pressure switch, tank level switch or a set of external relay contacts can be
used to control the F29. The supply to the external switch must be taken
from the LV terminal of the F29 when the controller is powered from the
mains or from a 24V source. The F29 must always be powered from the
same source as the supply to external switch. The supply to the remote
switch on the F29-12 (low voltage DC model) must be taken from the
supply positive terminal. In all cases the external switch return wire must
be connected to the Remote input (R) terminal on the F29. Relative to
neutral, the supply to the external switch will range from 12 to 24 VDC or
from 20V to 35V AC depending on the supply voltage.
WARNING: Never connect an external power source of any kind to the F29’s
remote input terminal.
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.
REMOTE INPUT
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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. This is well under the 5,000 Ohm limit. The
remote input to the F29 will operate properly provided the wires are
separated by sufficient distance that the capacitance between them is less
than 25nF. Capacitance should be measured between the wires when the
remote switch is open and it must be less than 25nF.
Cable Size square mm Resistance Ohms /1000M
0.2 95.30
0.5 36.20
0.75 24.13
1.0 18.10
1.5 12.10
Note: Use table as a guide only, cable resistance may vary depending on
the wire standard and construction.
EXAMPLE
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PLUG & PLAY CONNECTIONS
CONNECTIONS FOR A SINGLE PHASE PUMP
WIRING DIAGRAMS
All electrical wiring associated with
this controller must be carried out by
a qualified Electrician
Earth
Link
Optional voltage
free external input
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Pump Motor 1
110 ~ 240VAC 50 Pump Motor 2.4kW Max.
when the HD terminal is linked
This link wire must be used whenever
the controller is directly controlling a single
phase pump motor, as shown. Do NOT use the HD link
in 3 phase or single phase control circuit applications
Remote switches with
NO or NC voltage free contacts
Supply
110 ~ 240VAC 50
Active
Neutral
Pump Motor 2
Single Phase 110 ~ 240VAC Motor 3A
Max. when controlled directly
Positive
Negative
Supply
18 to 24 Volts AC or DC
LOW VOLTAGE SUPPLY
DUAL SINGLE PHASE PUMPS & 2 REMOTE INPUTS
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