KELCO F60 Mk2 Assembly instructions

KELCO F60 Mk2
DIGITAL PUMP CONTROLLER
INSTALLATION & PROGRAMMING
MANUAL
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au
Version 010319

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IMPORTANT: READ THIS FIRST
DO NOT EXPOSE THE F60 Mk2 TO VIBRATION. INSTALL ONLY IN
PIPEWORK THAT DOES NOT VIBRATE. Vibration will damage the
electronics within the F60 and will void your product warranty.
This F60 pump controller has been fully tested and calibrated. It is set to
mode 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 will run the pump using
its start-up timer. If it finds flow in the pipe system it will continue to run the
pump. If flow stops the pump will continue to run for 5 seconds, held on by
the F60’s run-on timer. If flow fails to return, the pump will be shut down
after the run-on period. Pressing and releasing the (R) button on the F60
will repeat this basic process.
THE BUTTONS
The F60 is controlled and configured using 4 onboard buttons.
(R) Reset button. Stops the pump(s) and restarts the F60 when released.
(˄) Up arrow button. For increasing program settings.
(˅) Down arrow button. For decreasing program settings.
(P) Programming button. For stepping through the menu and entering
settings into memory.
THE LIGHTS
The F60 includes 4 multicolour lights to indicate activity.
Flow: This light is GREEN when the F60 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.

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LCD SCREEN BACKLIGHT
The LCD backlight can be turned on or off.
To turn the light off press and hold down the (˅)button. Press and release
the (R) button. Release the (˅)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.
TEMPERATURE
The F60 monitors its internal temperature when running. Pressing the
(˅)button while the controller is powered up displays the current internal
temperature of the F60.
PRESS (and release) THE (P) BUTTON
When the F60 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 F60’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 F60
1) Do not install the F60 in a fully exposed outdoor location. The F60
is weatherproof, however, to ensure a long reliable life from it we
recommend it be protected from direct exposure to the sun and rain.
A skull cap is provided with the F60 and we recommend it be used to
protect the F60 when direct observation of the LCD screen is not
required.
2) Do not expose the F60 to freezing. If the pipework in which the F60
is installed freezes, the pressure sensor in the controller may fail. If
the F60 is to be used in areas where low temperatures will be
encountered, always lag the pipework for several metres either side
of the F60. Also lag the base of the F60 to prevent the unit and any
adjacent pipework from freezing.
3) Do not use this controller in hot water applications. The F60 is not
designed to be used in water hotter than 60ºC.

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4) Never expose the F60 to static or dynamic pressures greater than
20 Bars, 290 psi.
5) DonotinstalltheF60inasectionofpipethatissubjecttovibration.
Vibration will cause premature failure of the electronic components
within the F60.
6) Never install the F60 in the suction pipe of the pump or in any
location where it may be subject to partial vacuum conditions.

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LOCATION
The F60 should be installed in a straight section of pipe preferably with
5 diameters of straight pipe either side of the paddle. The F60 can be
installed in a suitable pipe socket, tapping saddle or pipe tee. The F60
should be installed in the discharge pipework of the pumping system,
either before or after the system’s air cell. If the system does include an
air cell a decision must be made as to which side of the air cell to locate
the F60. The fundamental way the system operates will depend on this
decision. The F60 should not be installed in the suction pipe of a pump as
it requires positive pressure to operate properly. The F60 can be installed
in either horizontal or vertical pipe. If it is installed in vertical pipe the flow
should preferably be in an upward direction. Do not install the F60 on the
underside of horizontal pipework.
WARNING: Never install the F60 in the suction pipe of the pump or
in any location where it may be subject to partial vacuum conditions.

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Controller
Discharge
Controller installed before the air cell
BEFORE THE AIR CELL
If the F60 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.
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.

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AFTER THE AIR CELL
If you install the F60 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.
Discharge
Controller
Controller installed after the air cell

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INSTALLATION
The F60 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.

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TRIMMING THE PADDLE
The paddle of the F60 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 the flow rate will only ever be fairly low, 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.
http://www.kelco.com.au/paddle-trimming-calculator-2
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 F60 are available from Kelco or from your distributor.
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 controller with the axis of the pipework. To do so will irreparably
damage the controller 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 F60. Never apply water pressure to the F60 unless
the electrical head is fitted and the M4 locking screw is in place and fully
tightened. The F60 can be installed in either vertical or horizontal pipe.
When installed in vertical pipework flow should preferably be in an upward
direction past the controller’s paddle. The F60 has a 1” BSP process
connection. A matching female threaded socket, pipe saddle or pipe tee
must be provided to fit the controller into pipework.
ATTACHING THE ELECTRICAL HOUSING
Once the paddle assembly has been installed, fit the electrical housing
onto the spigot on top of the paddle assembly. Take care that the sealing
O-ring is on the top stem of the paddle assembly is in location and in good

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order. 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. To secure the electrical
housing onto the paddle assembly, an Allen head cap screw is supplied.
The controller must be square to the axis of the pipework with the direction
of flow arrow pointing in the direction of flow.
With the electrical housing located on the spigot and in position, press
down with the flat of your hand on the top face of the electrical enclosure.
While pressing down, screw the 4mmAllen screw fully through the housing
using the 3mm Allen Key (supplied). Tighten the screw and then release
your hand from the top of the housing.
DETACHING THE ELECTRICAL HOUSING
WARNING: Always switch off the power and fully de-pressurise the
pipe system before attempting to remove the electrical housing.
To allow easy access to the controller’s paddle, the electrical housing of
theF60canbedetachedfromthepaddleassembly.Removingtheelectrical
housing allows access to the paddle without the need to disconnect wiring.
To remove the electrical assembly undo and completely remove the M4
Allen head locking screw. 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
paddlehousing. Simplyreversethisproceduretorefittheelectricalhousing
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.
SENSITIVITY ADJUSTMENT
Under the end of the electrical housing on the F60 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 wind the sensitivity adjustment screw

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anti-clockwise (outward) the force against the paddle that resists flow will
be reduced. 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 controller. In horizontal pipework with the F60 mounted vertically the
useable range of adjustment is approximately 8 turns. In vertical pipework
with the F60 installed horizontally the full 10 turn range can be utilised.
DUAL PUMP CONTROL Mode 5
The F60 is capable of controlling 2 pumps simultaneously. The pumps can
be of any required size and can be configured as a duty and standby set or
as a dual alternating set. The starting and stopping pressures for both
pumpscanbe setindependentlyof eachotherin anyrequiredconfiguration
within the overall pressure limits of the F60. The F60 detects flow at one
location in the pipework. This will normally dictate the location of the F60
in the overall system. For example, when used alone the F60 would
normally be mounted in the systems common discharge manifold. When
set up this way the F60 will not offer loss of flow protection to the individual
pumps, only to the overall system. A far better arrangement is to monitor
flow from each pump independently. To give each pump individual loss of
flow protection the F60 should be installed in the discharge pipe of one
pump and a basic flow switch installed in the discharge pipe of the second
pump.
Dual flow sensing can then be implemented by connecting the remote
mounted flow switch into the remote input terminal No1 of the F60. When
configured this way, The F60 can monitor flow at the two locations
simultaneously. Loss of flow from either or both pumps will shut the pumps
down if flow is lost.

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TYPICAL DUAL PUMP SET
A typical dual pump set is depicted in the accompanying sketch. The F60
and the F21 paddle flow switch are installed in the discharge pipes from
the pumps prior to their entry into the common discharge manifold.
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.

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All electrical work associated with the F60 must be
carried out by qualified electrical personnel and all
electrical work must conform to AS/NZ standards and
to local wiring rules.
WARNING
ELECTRICAL INSTALLATION
INTRODUCTION
When used with its HD terminal link in place, the F60 can directly control
single-phase pump motors to 2.4kW via Relay 1. No interposing contactor
is required for such applications. The F60 can also be used to control 3
phase pump motors of any size via an appropriate interposing contactor.
WARNING: The contactor control circuit must never exceed 240VAC.
Never connect the F60 and contactor coil directly across 2 phases of
the supply.
The F60 requires a stable 220V to 240VAC 50 supply when operated from
the mains. It can also be operated from an 18 to 24V AC or DC supply by
utilising the low voltage active terminal FELV and neutral terminal N (see
the included wiring diagrams). When operated from a low voltage DC
supply the terminals FELV 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
tobe usedin theinstallation. If thevoltage dropassociated withthe starting
of the pump motor is excessive the F60 may repeatedly reset and not
operate properly.

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THE HD (Heavy Duty) TERMINAL
The F60 pump controller 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 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 motor. The HD drive should not be used
when the F60 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 motor starts and
stops. It effectively handles the high inrush current associated with the
motor starting, and it provides a current path for the destructive back EMF
associated with the motor stopping.
To use the HD drive, place a heavy link wire between the HD terminal
and the Normally Open terminal of Relay 1.
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
mustneverbeconnectedtoanyexternaldevice. Undernocircumstances
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.

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Rubber Plug
Backing Washer
M20 Gland Nut
Plug unused cable glands
using the rubber plugs
(supplied). Fully tighten
the gland nut to seal the
unused cable port.
Crimp the ears of the
strain relief ring onto the
cable and pull the cable
back into the slots in the
gland housing.
Cable 7mm to 9mm diameter
Controller Housing
Rubber Grommet Backing Washer
4mm
BROWNOUT OR BLACKOUT
If a blackout or brownout occurs the F60 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 F60 will reboot, restart the pump and run
any timer settings from the beginning. Amanual reboot can be done at any
time by pressing and releasing the F60’s reset button.
CABLES
The F60 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 F60 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.

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VOLTAGE LIMITS ON TERMINALS A & N
Maximum Supply Voltage 260VAC 50/60Hz
Minimum Supply Voltage 110VAC 50/60Hz
VOLTAGE LIMITS ON TERMINALS FELV & N
Maximum Supply Voltage 25VAC 50/60Hz or 25VDC
Minimum Supply Voltage 18VAC 50/60Hz or 18VDC
CONTACT RATINGS FOR RELAYS 1 & 2
16A at 250VAC Resistive Load PF > 0.9
16A at 30VDC Resistive Load PF > 0.9
50mA at 5VDC Minimum Load
SUPPLY VOLTAGE LIMITS
RELAYS
The F60 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 F60 as a dual pump controller, relay 2 is used to
control the second pump.
With the HD terminal linked to the NO terminal of Relay 1, the F60
can directly control a single phase motor up to 2.4kW. 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.
MAXIMUM PUMP MOTOR LOAD FOR RELAY 1
10A at 240VAC 2.4kW Inductive Motor Load
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.

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POWERING THE F60
The power required to drive the F60 depends on 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 requirement
will reduce. For example, at 30°C the power requirement will be
approximately3%lessthanthevaluesgiveninthetable. Themeasurements
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.
POWER REQUIRED TO DRIVE THE STANDARD F60
24VDC Supply to FELV & N Maximum 68mA 1.63Watts
24VAC 50/60Hz Supply to the
FELV & N Terminals Maximum 108mA 2.34Watts
220VAC 50Hz Supply to A& N Maximum 87mA 2.00Watts
240VAC 50Hz Supply to A& N Maximum 94mA 2.54Watts
POWER REQUIRED TO DRIVE THE 12VDC F60-12
With Both Relays Closed Maximum 68mA 0.81Watts
With One Relay Closed Maximum 52mA 0.62Watts
Quiescent State (relays open) Maximum 25mA 0.30Watts

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REMOTE INPUTS
WARNING: The low voltage source available at the FELV terminal is
non-isolatedand must beregardedas operating at fullmains potential
whenever the F60 is powered from the mains. FELV means Functional
Extra Low Voltage and refers to a non-isolated extra low voltage
source.
The F60 has two remote inputs.marked RMT1 and RMT2. Remote 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 F60. Anormally open remote reset
switch can be used to reboot the F60 by connecting it to RMT2.
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. The supply
to the external switch must be taken from the FELV terminal on the F60
when the controller is powered from the mains or from a 24VAC source.
The F60 must always be powered from the same source as the supply to
externalswitch. ThesupplytotheremoteswitchontheF60-12(lowvoltage
DC model) must be taken from the supply positive terminal. In all cases
the external switch return wire must be connected to the correct remote
input terminal on the F60. The supply to the external switch will range from
12 to 24 VDC or from 20 to 35V AC depending on the supply voltage.
WARNING: Never connect an external power source of any kind to
the F60’s remote input terminals.
The remote switch can be installed some distance from the F60. 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 F60’s remote inputs. For cable
runs longer than 150 metres we suggest using 2 separate wires to reduce

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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.
EXAMPLE
A water tank is located 2000 metres from the F60. Two separate wires
each 0.2mm^2 are run to the remote tank (total wire length is 4000 meters).
The resistance as measured across the 2 wires back at the F60 (with the
tank level switch closed) is 382 Ohms. This is well under the 5,000 Ohm
limit. The remote input to the F60 will operate properly provide 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 in Ohms per 1000
Metres
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.