KELCO F60 Installation manual

KELCO F60
DIGITAL PUMP CONTROLLER
PROGRAMMING INSTRUCTIONS
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au

Table Of Contents
Introduction 1
Programming the Controller 2
F60 Modes and Functions, Mode 1 3
Modes 2 & 3 4
Pressure System Operation 5
Pressure Settings 6
Pre Start Delay Timer 7
Running on the Snore 8
Delayed Restarting 9
Cyclic Running 10
Run Dry Auto Restart 11
Anti-Cycling 12
Burst Pipe Detector 13
LCD Screen Back Light 14
Leak Detector 15
Remote Input 15
Program Lock 16
Please Read Me First
The F60 pump controller is supplied pre-loaded with a simple program. It
is set to mode 1 and it has it’s startup and run-on timers both set to 10
seconds. All other functions are turned off or set to zero. Provided the F60
is unlocked you can restore it to this default state at any time by pressing
and holding down the (P) button and pressing the (R) reset button at the
same time. Doing this removes any settings you may have entered and
restores the controller to its original default state.

Introduction
The F60 pump controller includes a set of functions that can be set up to control
a pump. The functions range from a simple override on start timer that allows a
pump to start in spite of an initial lack of ow, through to sophisticated cyclic
running and stopping sequences. The functions are independently accessible
and adjustable through the F60’s simple programming interface. The pages that
follow set out what each function does and how to set it up.
The actual selection of a suitable mode of operation and the functions used from
a specic mode must be decided prior to programming and will depend on what
level of control the pumping system requires. In order to achieve the best
performance from this pump controller observe the following basic rules.
1) Use the least number of functions possible. Do not program in functions you
do not specically require, as to do so will make the system’s operation
unnecessarily complicated and may introduce unpredictable interactions between
the various functions.
2) When moving from mode to mode and from function to function always reset
time and pressure values back to zero before moving on. Do not leave timers
setup with some value entered in and subsequently decide not to use that specic
function. If you do this then enter zero values into the timers and pressure setting
before exiting the unrequired function. Provided the f60 is unlocked, a quick way
to reset it and clear out any unwanted settings is to press and hold down the (P)
button while also pressing the (R) reset button. Doing this clears all settings out
of the controller and loads in a very basic mode 1 program.
3) Set realistic and sensible values into the various functions. For example do
not set a pump to stop at a lower pressure than it is set to start at. Always set the
controller’s starting and stopping pressure differential to as wide a difference as
possible.
1

Programming The Controller
This pump controller is fully programmable; it accepts input via 4 push buttons.
The buttons are marked P for programming, Up and Down for data entry and a
reset button R. Pressing the P button during normal operation stops the pump and
allows entry to the controller’s menu. Subsequent pressing of the P button steps
you through the menu from one option to the next. Each option can be adjusted
using the up and down buttons.
Pressing the P button stores the settings you make into the F60’s memory and
steps you to the next option. When you reach the end of the option list the controller
asks you to press the reset button to accept the settings you have made and to
resume normal running. You can automatically save any changes you have made
and exit out of the menu at any stage during programming by simply pressing the
reset button. The settings you make are non volatile and are recorded in the
controller’s memory. Your setting will not be lost if the controller is switched off for
extended periods. When the unit is switched back on the controller will automatically
boot up and operate using the setting recorded in its memory.
The Three Operating Modes
The F60 can be set to operate in one of 3 fundamental operating modes. An initial
choice must be made as to how you want to control the pump. Once you have
made your choice, the F60’s menu will ask you a series of questions that relate to
the specic mode you have chosen. A table of the available functions is included
here to assist with selection of a suitable mode. The 3 modes are: -
Mode 1 Timer Control
In this operating mode the controller operates under time based control and
ignores the system pressure. Mode 1 provides you with a set of basic timers that
includes a start-up timer to allow the pump to initially start regardless of lack of
ow, a snore timer to allow the pump to run partially dry, a run-on timer to ignore
short term interruptions to ow. In addition delayed restarting is available as is
anti-cycling and burst pipe detection. In basic mode the controller will start the
pump each time power is switched on or each time water ow pushes the paddle
forward. The controller can also be started using an external input from a remote
switch. See the section on remote input for more information.
2

F60 Modes & Functions
MODE 1 2 3
Functions (# Settable)
# Select pressure units kPa or psi Y Y Y
# Pre-start delay timer Y Y Y
# Start-up timer Y Y Y
# Run on the snore timer Y Y Y
# Run-on timer Y Y Y
# Delayed re-starting timer Y Y Y
# Starting pressure Y Y
# Stopping pressure Y
# Cyclic running and stopping timers Y Y
# Burst pipe detection Y Y Y
# Auto restart if run dry Y Y
# Anti-cycling Y Y Y
# Leak detector Y
# Starts the pump at a preset low pressure Y Y
# Stops the pump at a preset high pressure Y
Stops the pump if ow stops. Y Y Y
Displays the system pressure in preferred units Y Y Y
Displays the high & low pressure set points Y
Can start or start & stop the pump using an external
switch (with voltage free contacts) Y Y Y
Starts & stops the pump on ow regardless of pressure Y
In Mode 1 the controller does not utilise its internal pressure sensor to control the
pump. Pump control is solely based on ow and time. The controller’s pressure
sensor is used to display the system’s dynamic pressure on its LCD screen during
normal operation.
3

Mode 2 Flow Control
In this mode the F60 will start the pump each time the pressure falls below a
preset value or whenever the controller’s paddle is pushed to the on position by
ow. It will then run the pump entirely on ow. Unlike a conventional pressure
system that operates between a low pressure cut-in and a high pressure cut-out,
in mode 2 the controller only uses the pressure set point to start the pump, not to
stop it.
Once started, the F60 runs the pump while ever ow is present, thus providing a
relatively steady constant ow. The pump is only shut down when ow stops or if
the pump runs dry. A momentary contact external switch can also be used to
trigger the starting and or the stopping of the pump in this operating mode.
Mode 3 Pressure Control
If this mode is chosen the controller will start and stop the pump under the control
of the F60’s built in pressure sensor. A high pressure cut-out point and low
pressure cut-in point are programmed into the controller’s memory and thereafter
the pump is run within these pressure limits. If the pressure rises above the high
pressure set point the pump will shut down. If the pressure falls to below the low
pressure set point, the pump will start. If the pump runs dry, this is sensed as a
combination of loss of ow and low pressure. In this situation the pump will shut
down and go into alarm mode.
In mode 3 the pump controller can also be connected to an external switch. The
pump controller will start the pump each time the external switch closes its
contacts. The contacts of the external switch can be set to only operate the pump
while they remain closed or they can be set to only trigger the starting of the pump
and not its stopping. Since the F60’s remote input operates at low voltage and
low current, a low Wattage external switch, such as a tank level switch can be
used to control a large powerful pump without the need for an interposing pump
starter or relay. See the section on page 15 detailing the use of the remote input.
4

The Options in Detail
Pressure System Operation
If operated in mode 3 the F60 will only start the pump on ow on a rising pressure.
Consider a standard pressure system operated through a pressure switch. The
pump will start each time the pressure switch closes its contacts and stop each
time the pressure switch opens its contacts. This means that in a system with a
large air cell the pump once started will run continuously until the system is fully
pressurised, regardless of demand. The F60 operates in a different way.
The pump will start at a settable low pressure. It will run while ever ow is present
and only stop when ow stops or the pressure rises to whatever you have set its
high pressure cut-out to. If there is no ow demand the pump will only run on for
whatever time you have set on the run-on timer, perhaps a few seconds and then
it will stop. It will not pump continuously until the high pressure limit is reached,
as a normal pressure system will.
If a valve subsequently opens, ow will be sensed and the pump will instantly
start. The effect of this is to give the user a relatively constant pressure. Each
time the pump starts it does so at the pressure it last stopped at, rather than only
starting from low pressure. With frequent opening and closing of valves the system
pressure may rise and eventually reach the set cut-out pressure.
The pump will then stop regardless of any ow demand. Thereafter any ow
demand will not start the pump. In other words in this operating mode the F60 will
not start a pump on ow on a falling pressure, only on a rising pressure. This is
to prevent the pump from hunting on and off around the high pressure cut-out
point. On a falling pressure demand will be met by draw off from the system’s air
cell only. Once the system’s pressure falls to whatever pressure you have set the
cut-in pressure to, the pump will start and again revert to starting and stopping on
ow demand.
On pressing the P button you are presented with a Kelco splash screen. Pressing
P again steps you to a screen that displays the F60’s model number. The screen
that follows allows you to select the pressure units you prefer, either kPa or psi.
Use the up or down keys to select between the two units. Once you have made
your choice press the P button to step to the next selection which is the pre-start
delay timer. Use the up and down keys to select Yes or No for this option.
5

If you choose yes, the screen that follows will ask you to enter the required time
delay. Use the up and down keys to set the required delay and then press P to
record the settings to memory and move to the next option. The next screen you
are presented with is the mode selection screen. Press P to step to the rst
choice which is Mode 1 Timer Control. Use the up and down keys to view the
other two modes, Mode 2 Flow Control and Mode 3 Pressure Control. Once you
have decided which mode you require, press P to accept your selection and move
to the next screen. From this point on the functions available to you will depend
on which mode you have chosen.
As you step through the available choices certain functions will be available to
you to use and certain functions will not appear. Some functions are common to
all modes and some are mode specic. The controller’s menu has sufcient
intelligence to identify selections you make and to only make available to you
functions that will work with the choices you have made. The functions that follow
are mode specic and may or may not be available to you depending on the
choices you have made up to this point.
Pressure Settings
If you select mode 2 or 3 from the mode menu, the screens that follow will ask you
to enter starting and possibly stopping pressure in whatever pressure units you
have chosen to use. Enter sensible pressures that are within the range of the
pump and include a reasonable differential between starting and stopping
pressures. If you set the starting pressure higher than the stopping pressure, the
F60 will not operate and will display a warning screen to the effect that the
pressures have to be set correctly.
If you set the pressure differential (the difference between the starting and stopping
pressure) too small the system may hunt on and off. This condition will be more
pronounced if the system has no air cell or the capacity of the pipework is small.
The F60’s ability to operate on a close differential can be a major advantage in
certain circumstances.
In theory the cut-out pressure of the F60 can be set to 1kPa higher than the cut-in
pressure. With such a setting the controller will operate on a differential of 1kPa.
For actual practical usage, background pressure uctuations and temperature
variation in the system will reduce the actual usable minimum pressure differential
to perhaps 10 or more kPa which is still considerably less than that of a conventional
pressure switch.
6

Pre-Start Delay Timer
The pre-start delay timer delays the starting of the pump for a selectable period.
It can be set from zero to 240 seconds (4 minutes) in one second increments. If
you choose to use this timer the actual starting of the pump will be delayed by
whatever delay you set this timer to. Each time the controller is switched on it
boots up and is prevented from starting the pump for the set time period. As soon
as the set time has elapsed the pump will start and run normally, given there is a
demand for water. The pre-start timer can be used to allow peripheral equipment
time to boot up. For example, some VS drives require a few seconds to stabilise
and the F60’s pre-run timer can hold off the starting of the pump until the whole
system has stabilised. The pre-start timer can also be used to stage or stagger
the starting of multiple pumps. It is often desirable to avoid the high current draw
of multiple motors starting together, and the pre-start timer can facilitate this
function.
Start Up Timer
The F60 uses a paddle to detect ow. The paddle is held in the no-ow position
by an adjustable magnetic screw that is located in a port under the electrical
housing of the controller. If ow pushes against the paddle, the paddle moves.
The movement is detected by the controller and identied as ow. Initially in a
system that is not running or has all its valves shut, there will be no ow and the
controller’s paddle will be in the off or no ow position. In order to override this
initial off state and allow the pump to start, the controller uses the start-up timer.
The timer ignores the initial off state of the paddle and allows the pump to run for
a settable time. As soon as ow is detected the start timer terminates its run and
hands control of the pump over to the paddle. The startup timer in the F60 is
adjustable from 0 to 240 seconds (0 to 4 minutes) in 1-second increments. The
value you enter will depend entirely on your pump system. For a fully primed
pressure system or transfer pump, the start-up timer may only require one or two
seconds to establish ow. In a submersible bore pump installation with a self-
draining riser, it may take several minutes to establish ow past the paddle. If the
start-up timer is set to zero the pump controller behaves as a simple ON/OFF ow
switch, responding solely to the state of its paddle.
In normal operation the F60 will display the system’s dynamic pressure in whatever
pressure units you have chosen whenever it is running normally or is waiting to
start. It will also display any pressure set points you have entered. For example,
when operating in mode 3 the LCD screen will display the current system pressure
and the high and low pressure set points. From the display it is then a simple
matter to watch the system pressure rise or fall toward the preset trip points that
you have set the system to operate within.
7

Run-on Timer
Running On The Snore
The snore timer allows the controller to ignore continuous paddle bounce due to
entrained air or gas in piping systems. In situations where entrained gas or air in
the pipework is an ongoing problem and is constantly present in a pipe system,
the snore timer allows the controller to ignore the gas bubbles and keep the pump
running stably. When entrained gas moves past the paddle of the F60 the paddle
bounces back and forward. The snore timer monitors the movement of the paddle
and each time the paddle bounces, the snore timer resets itself and commences
its timed run again.
The automatic resetting action ensures the pump controller does not identify the
minor interruptions to ow as a dry run situation. The snore time can be set to any
value from 0 to 240 seconds (0 to 4 minutes) in increments of 1 second. The F60
identies a dry run situation when the paddle has remained in the off position for
longer than the time you have set on the snore timer. If the off time exceeds the
snore timer’s setting the F60 shuts down the pump and goes into alarm mode.
Care should be taken when using the snore timer to ensure the pump being used
is suitable for being run when partially dry. Please contact your pump supplier
before using the snore timer to ensure your pump is suitable for such operation.
For most applications the snore timer should be initially set to a few seconds only.
In normal operation, in systems where entrained gas is not an issue, the F60
digital pump controller’s built in run-on timer can be set to ignore minor interruptions
to ow. For example, if air trapped in the pipework passes the controller’s paddle,
the paddle will momentarily swing into the no ow position. This would normally
cause the controller to shut down the pump. The run-on timer lets the controller
ignore such minor uctuations in ow. Once triggered, the run-on timer simply
runs for whatever time you have set it to. During this run period it ignores the state
of the paddle and simply runs the pump. At the end of its set run time, it looks at
the state of the paddle and if ow is present, resumes normal operation. If ow is
not present at the end of the run-on time, the controller shuts down the pump and
goes into alarm mode because it considers the pump to be running dry. It is
important to note that unlike the snore timer, the state of the paddle is not monitored
continuously while the run-on timer is running. The paddle can bounce back and
forward and the run-on timer will ignore it.
8