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