KELCO F60 MK3 Assembly instructions

KELCO F60 MK3
DIGITAL PUMP CONTROLLER
INSTALLATION & PROGRAMMING
MANUAL
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au

2
ELECTRICAL AND MECHANICAL LIMITS OF THIS CONTROLLER
DO NOT EXCEED THESE LIMITS UNDER ANY CIRCUMSTANCES
Ambient temperature T50 (0°C ~50°C)
Ingress Protection IP64
Feature of automatic action Type 1.B
Number of automatic cycles (A) for
each automatic action
5,000 cycles
Type of terminal Screw terminal block, type Y attachment
Load Termination Function
Input Input 1 HD /A /N AC 220-240V, 50Hz/60Hz
Input 2 A /N AC 220-240V, 50Hz/60Hz
Input 3 LV/N AC18-24V, 50Hz/60Hz; DC18-24V
Input 4 RMT1 /RMT2 Remote inputs sourced from LV terminal
Output Relay 1 (SPDT
pump control relay)
R1NO/R1COM/
R1NC VDE
40015012
NO contacts, AC240V, 50Hz, 10A
NC contacts AC240V,50Hz 3.5A
Duty factor, 5s ON, 5s OFF
Ralay 2 (SPST
alarm relay)
R1NO/R2COM
VDE 40015012
AC240V, 50Hz/60Hz; 3.5A
Duty factor, 5s ON, 5s OFF
Motor load Single phase motors (Single phase pump motors up to 2.4kW
maximum)
Three phase motor Via a suitable interposing contactor
IMPORTANT: Input 1 or 2 shall not be connected while the input 3 or
4 are connected
TEMPERATURE LIMITS
This F60 MK3 Pump Controller is designed to operate in an ambient
temperature range 1°C to 50°C. Process liquid temperature must not
exceed 60°C. Operation of this pump controller outside these temperature
limits may damage the controller and void any warranty on the product.
PRESSURE LIMITS
This F60 MK3 Pump Controller is designed to operate in the pressure
range 0 to 2000kPa, 0 to 20 Bars, 0 to 290 psi. It must never be exposed
to static or dynamic pressures in excess of 20 bars, 290 psi. The F60 MK3
must never be exposed to negative pressure. Never install the F60 MK3
on the suction pipe work of a pump. Operation outside the stated pressure
limits may damage this product and void any warranty,

3
IMPORTANT: READ THIS FIRST
DO NOT EXPOSE THE F60 MK3 TO VIBRATION. INSTALL ONLY IN
PIPEWORK THAT DOES NOT VIBRATE. Vibration will damage the
electronics within the F60 MK3 and will void your product warranty.
This F60 MK3 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 o󰀨. On start up the F60 MK3 will run the pump
using its start-up timer. If it nds ow in the pipe system it will continue
to run the pump. If ow stops the pump will continue to run for 5 seconds,
held on by the F60 MK3’s run-on timer. If ow fails to return, the pump
will be shut down after the run-on period. Pressing and releasing the (R)
button on the F60 MK3 will repeat this basic process.
THE BUTTONS
The F60 MK3 is controlled and congured using 4 onboard buttons.
(R) Reset button. Stops the pump(s) and restarts the F60 MK3 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 MK3 includes 4 multicolour lights to indicate activity.
Flow: This light is GREEN when the F60 MK3 detects ow and RED when
no ow 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 o󰀨
when the remote is open. The light is RED when remote input No. 2 is
closed and o󰀨 when the remote is open. This light is PURPLE when both
remote inputs 1 & 2 are closed.

4
LCD SCREEN BACKLIGHT
The LCD backlight can be turned on or o󰀨.
To turn the light o󰀨 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 o󰀨. The light
can be left permanently on or o󰀨 as required.
TEMPERATURE
The F60 MK3 monitors its internal temperature when running. Pressing the
(˅) button while the controller is powered up displays the current internal
temperature of the F60 MK3.
PRESS (and release) THE (P) BUTTON
When the F60 MK3 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 MK3’s memory. The memory is non-volatile and settings are
retained when power is o󰀨. 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 MK3
1) Do not install the F60 MK3 in a fully exposed outdoor location. The
F60 MK3 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 MK3 and we recommend it
be used to protect the F60 MK3 when direct observation of the LCD
screen is not required.
2) Do not expose the F60 MK3 to freezing. If the pipework in which
the F60 MK3 is installed freezes, the pressure sensor in the controller
may fail. If the F60 MK3 is to be used in areas where low temperatures
will be encountered, always lag the pipework for several metres either
side of the F60 MK3. Also lag the base of the F60 MK3 to prevent the
unit and any adjacent pipework from freezing.
3) Do not use this controller in hot water applications. The F60 MK3
is not designed to be used in water hotter than 60ºC.

5
4) Never expose the F60 MK3 to static or dynamic pressures greater
than 20 Bars, 290 psi.
5) Do not install the F60 MK3 in a section of pipe that is subject to
vibration. Vibration will cause premature failure of the electronic
components within the F60 MK3.
6) Never install the F60 MK3 in the suction pipe of the pump or in any
location where it may be subject to partial vacuum conditions.

6
LOCATION
The F60 MK3 should be installed in a straight section of pipe preferably with
5 diameters of straight pipe either side of the paddle. The F60 MK3 can
be installed in a suitable pipe socket, tapping saddle or pipe tee. The F60
MK3 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 MK3. The fundamental way the system operates will depend on
this decision. The F60 MK3 should not be installed in the suction pipe
of a pump as it requires positive pressure to operate properly. The F60
MK3 can be installed in either horizontal or vertical pipe. If it is installed in
vertical pipe the ow should preferably be in an upward direction. Do not
install the F60 MK3 on the underside of horizontal pipework.
WARNING: Never install the F60 MK3 in the suction pipe of the
pump or in any location where it may be subject to partial vacuum
conditions.

7
BEFORE THE AIR CELL
If the F60 MK3 is installed before the air cell in the system it will only start
the pump on pressure since the initial ow 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.

8
AFTER THE AIR CELL
If you install the F60 MK3 in the pipework after the air cell it will start the
pump each time ow 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 ow is sensed.

9
INSTALLATION
The F60 MK3 pump controller is supplied as two separate assemblies, the
paddle assembly and the electrical housing. The paddle assembly should
be installed in the pipework rst.

10
VERY IMPORTANT SAFETY NOTE :
A pressure relief valve should be tted to any system that can exceed the
pressure rating of any component on that system. Alternately, always
conrm that the pressure safety limits of individual items are compatible
and not compromised without the tting of appropriate safety devices, i.e.
a Pressure Relief Valve (PRV). A PRV should be tted to every system to
ensure the system can not run against a shuto󰀨 head. A correctly set PRV
will ensure the system can’t overheat the pump in the event of this F60
MK3 or any other part of the system locking the pump on.