KELCO F60 User manual

KELCO F60
DIGITAL PUMP CONTROLLER
INSTALLATION INSTRUCTIONS
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au
Version 180516

VERY IMPORTANT
This Kelco controller has been fully tested and calibrated. It is
presently unlocked and has a simple program loaded. It is set to
operate in a basic way with most of its special functions and features
switched o󰀨.
On start up this controller will run the pump using its start-up timer. If it
nds normal operating conditions in the pipe system it will continue to run
the pump. If pressure or ow conditions change the pump will continue to
run for a short period held on by the controller’s built in run-on timer. If
acceptable conditions fail to return the pump will be shut down after the
run-on time period. Pressing the red reset button on the controller’s lid or
resetting the power will repeat this basic process.
To change the functions of this controller please rst read the programming
book supplied with this unit.
IMPORTANT
DO NOT EXPOSE THIS CONTROLLER TO VIBRATION. INSTALL ONLY
IN PIPEWORK OR MANIFOLDS THAT DO NOT VIBRATE. Vibration will
damage the sensitive electronics within the controller and will void your
product warranty.

Table Of Contents
Warning Symbols Explained.......................................................... 1
Important Safety Instructions......................................................... 2
Overview........................................................................................ 3
Installing the F60........................................................................... 4
Before or After the Air Cell............................................................ 5
Warning Message.......................................................................... 6
Installation...................................................................................... 7
Aligning Paddle Assembly............................................................. 8
Locking the Electrical Assembly Onto The Paddle Assembly....... 9
Trimming the Paddle...................................................................... 10
Detaching the Electrical Housing.................................................. 11
Sensitivity Adjustment.................................................................... 12
Limitations...................................................................................... 13
Table of Limitations........................................................................ 14
Electrical........................................................................................ 15
The HD Heavy Duty Terminal........................................................ 16
Brownout or Blackout.................................................................... 17
Cable Gland Assembly................................................................... 18
Electrical Limits............................................................................. 19
Remote Input ................................................................................ 20
Wiring Diagrams ........................................................................... 26
The 12VDC F60 Pump Controller.................................................. 28
F60 Layout..................................................................................... 29
Table of Controls and their Functions............................................ 30
Maintenance, Spare Parts, Warranty............................................. 31

This symbol is intended to alert the user
to the presence of important operating
and maintenance instructions in the
literature accompanying the pump
controller
WARNING
This symbol is intended to alert the user
to the presence of un-insulated
“dangerous voltage” within the pump
controller’s enclosure that may be of
su󰀩cient magnitude to constitute a risk
of severe electric shock.
WARNING
1

IMPORTANT SAFETY
INSTRUCTIONS
• Read these instructions.
• Do not modify this controller in any way.
• Keep these instructions.
• Heed all warnings.
• Follow all instructions.
• Do not allow water to enter this controller.
• Install this controller per the manufacturer’s instructions.
• Do not install this controller near any heat source such as radiators, gas
heaters, stoves, or any other appliance that produces heat.
• Do not drill holes in this controller’s casing.
• Refer all installation and servicing to qualied service personnel.
• Servicing is required when the controller has been damaged in any way,
s u c h a s e x p o s e d t o  r e , d r o p p e d , h a d o b j e c t s d r o p p e d o n i t o r b e e n
exposed to moisture or water when the controller’s lid is removed.
Please read these installation and operating
instructions fully and carefully before installing
or servicing this controller. The F60 Pump
Controller is a mains voltage device. Death or
serious injury may result if this product is not
correctly installed and operated.
WARNING
2

Overview
The F60 digital pump controller is a powerful exible controller that can be
congured in a variety of ways to control a pump and to protect it against running
dry. The controller can be set to operate in one of four fundamental modes. Within
each mode a number of functions can be selected using the controller’s simple
programmable interface. This document sets out in detail the installation and
functions of the controller and some of the main ways in which it can be used in
pumping and irrigation systems.
Without its lid in place the F60 is not water
resistant and presents a potential shock
hazard. Take great care not to splash water
onto the F60 when the lid is not in place.
Always replace the lid and fully tighten its 6
securing screws immediately after any
changes to the controller’s settings are
made.
WARNING
3

INSTALLING THE PUMP CONTROLLER
Location
Install this controller in a location that is sheltered from direct exposure to the
weather. The F60 is weatherproof; however, to ensure a long reliable life from the
controller we recommend it be protected from direct exposure to the sun and rain.
Intense sun light will eventually cause discoloration of the clear lid on the controller
and will also degrade its LCD screen. It is therefore advisable to always protect
the controller from the weather with some form of shielding.
The F60 should be installed in a straight section of pipe preferably with 5 diameters
of straight pipe either side of the paddle. The controller can be installed in a
suitable pipe socket, tapping saddle or pipe tee. The controller 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 has to be made
as to which side of the air cell to locate the controller. 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 ow must be in an upward direction. Do not install this controller
on the underside of horizontal pipework.
4
DO NOT INSTALL THE F60 IN ANY LOCATION THAT EXPOSES IT
TO DIRECT SUNLIGHT. IN A FULLY EXPOSED INSTALLATION
ALWAYS PLACE SOME FORM OF SHIELDING OVER THE
CONTROLLER TO PROTECT IT FROM DIRECT EXPOSURE TO
THE SUN. FAILURE TO PROTECT THE CONTROLLER FROM
DIRECT EXPOSURE TO THE SUN MAY CAUSE IT TO OVERHEAT
AND MAY REDUCE ITS OPERATING LIFE.
VERY IMPORTANT

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 draw o󰀨 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.
After The Air Cell
If you install the F60 in the pipework after the air cell the controller 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 fairly steady pressure and to start each time
ow is sensed.
DISCHARGE
PUMP
AIR CELL
REMOTE
FLOW
TIMER
P
PUMP
SUCTION
CONTROLLER
CONTROLLER INSTALLED BEFORE THE AIR CELL
DISCHARGE
PUMP
AIR CELL
SUCTION
CONTROLLER
CONTROLLER INSTALLED AFTER THE AIR CELL
5

After programming the F60 always replace its lid
and fully tighten all 6 securing screws. Also ensure
all cable glands are fully tightened. Never leave
the lid o󰀨 the controller for extended periods.
Without its lid in place the F60 is not water resistant
and presents a potential shock hazard. Take great
care not to splash water onto the controller when
the lid is not in place. Without its lid the controller
is not weather or insect proof and presents a
potential shock hazard that may result in death or
serious injury.
WARNING
6

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 rst and the electrical housing should then be tted onto the spigot
on top of the paddle assembly, taking care that the sealing O-ring is on the stem
and is in location and in good order. There is a at 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 at 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.
With the electrical housing located on the spigot and in position, press down with
the at of your hand on the top face of the lid of the electrical enclosure. While
pressing down, screw the 4mm Allen 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. Pressing down with your hand on the housing preloads
the O-ring seal between the housing and the paddle assembly. It enables the M4
Allan screw to easily screw fully through the side of the housing.
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.
Never apply water pressure to the controller unless the M4 locking screw is in
place and fully tightened (see sketch for details). To t the paddle assembly into
the pipework use a suitable spanner and use the spanner ats provided on the
paddle assembly (directly above the process connection thread).
The F60 can be installed in either vertical or horizontal pipe. When installed in
vertical pipework ow must be in an upward direction past the controller’s paddle.
The F60 may have been supplied with either a ¾” or 1” BSP or NPT process
connection. A matching female threaded socket or pipe tee must be provided to t
the controller into pipework.
7