KELCO IPG20 Mk2 Assembly instructions

KELCO IPG20 Mk2
INTELLIGENT PUMP GUARD
INSTALLATION & PROGRAMMING
MANUAL
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au
Version 150119

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VERY IMPORTANT SAFETY NOTICE
PLEASE READ THIS BEFORE INSTALLING THIS CONTROLLER
The IPG20 Mk2 is an industrial control device. It is specically designed
for use in dairy and agricultural applications. It must never be used for any
application other than for the aforesaid purposes. The installation,
commissioning of this pump controller requires extensive knowledge of
pump engineering and electrical engineering. Installation must always be
carried out by a qualied pump engineer and all electrical work associated
with this controller must be carried out by a licensed electrician. This
industrial control device must not be operated by persons (including
children) with reduced physical or mental capabilities, or lack of experience
and knowledge, unless they have been given supervision or instruction
concerning the use of this pump controller by a person responsible for their
safety.

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IMPORTANT: READ THIS FIRST
DO NOT EXPOSE THE IPG20 Mk2 TO VIBRATION. INSTALL ONLY IN
PIPEWORK THAT DOES NOT VIBRATE. Vibration will damage the
electronics within the IPG20 and will void your product warranty.
OVERVIEW
The IPG20 Mk2 intelligent pump guard is a pressure and ow based device
that “learns” the operating pressure each time the system is started. This
allows for nely targeted parameters where any signicant variation in the
operating pressure or loss of ow will trigger an alarm and shut the system
down.
Because the operating pressure will change each time the irrigator or
pods are moved to a di󰀨erent hydrant or hydrant group, or even a di󰀨erent
height on the same hydrant, it is normally impossible to give a high degree
of protection against over pressure due to a blockage or low pressure
due to a leak. With the IPG20 each time the pumping system is started
and after the operator has veried the system is running with no problems
the learning phase of the controller can be instigated, either manually, or
automatically, after a suitable time. The controller then starts to “learn”
the operating pressure. If a stable pressure is reached within the allotted
time the switch will lock this pressure in as the set point and apply the
predetermined under and over pressure settings. If there is no expected
change of pressure; eg. xed sprinklers, stationary irrigator or irrigator on
at land, then the low pressure and high pressure margin can be set very
close to the set point.
With a travelling irrigator Auto Terrain Compensation should be selected.
The switch then adjusts itself automatically to compensate for changes
in contour. This allows for a very small over and under margin, typically
10kPa or less, which gives a very high degree of protection against leaks
or blockages.

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THE BUTTONS
The IPG20 is controlled and congured using 4 onboard buttons.
(R) Reset button. Stops the pump and restarts the IPG20 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 IPG20 includes 4 multicolour lights to indicate activity.
Flow: This light is GREEN when the IPG20 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.
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 IPG20 monitors its internal temperature when running. Pressing the
(˅) button while the controller is powered up displays the current internal
temperature of the IPG20.
PRESS (and release) THE (P) BUTTON
When the IPG20 is powered up, pressing the (P) button, holding it down

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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 iPG20’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 IPG20
1) Do not install the IPG20 in a fully exposed outdoor location. The
IPG20 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 IPG20 and we recommend it be
used to protect the IPG20 when direct observation of the LCD screen
is not required.
2) Do not expose the IPG20 to freezing. If the pipework in which the
IPG20 is installed freezes, the pressure sensor in the controller may
fail. If the IPG20 is to be used in areas where low temperatures will be
encountered, always lag the pipework for several meters either side
of the IPG20. Also lag the base of the IPG20 to prevent the unit and
any adjacent pipework from freezing.
3) Do not use the IPG20 in hot water applications. The IPG20 is not
designed to be used in water hotter than 60ºC.
4) Never expose the IPG20 to static or dynamic pressures greater
than 20 Bars, 290 psi.
5) Do not install the IPG20 in a section of pipe that is subject to
vibration. Vibration will cause premature failure of the electronic
components within the controller.
6) Never install the IPG20 in the suction pipe of the pump or in any
location where it may be subject to partial vacuum conditions.
LOCATION
Install this controller in a location that is sheltered from direct exposure to
the weather whenever possible. The IPG20 is weatherproof and can be

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used in fully exposed locations; however, to ensure a long reliable life from
the controller we recommend it be protected from direct exposure to the
sun and rain. Intense sunlight 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 using the clip-
on skull cap supplied with the controller.
The IPG20 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. The
IPG20 should not be installed in the suction pipe of a pump as it requires
positive pressure to operate properly. The IPG20 can be installed in either
a horizontal or vertical pipe. If it is installed in a vertical pipe the ow must
be in an upward direction. Do not install this controller on the underside of
horizontal pipework.
WARNING: Never install the IPG20 in the suction pipe of the pump or
in any location where it may be subject to partial vacuum conditions.

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INSTALLATION
The IPG20 pump guard 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
the spanner ats provided on the paddle assembly (directly above the
process connection thread).
The IPG20 can be installed in either vertical or horizontal pipe. When
installed in vertical pipework ow must be in an upward direction past the
controller’spaddle. TheIPG20issuppliedwitha1”BSPprocessconnection.
A matching female threaded socket or pipe tee must be provided to t the
controller into pipework.
The IPG20 is supplied with one paddle to suit pipe sizes 25mm and greater,
and two trailing wires to suit pipe sizes from 65mm - 100mm ID, subject to
velocity.

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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).

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TRIMMING THE PADDLE
The polypropylene paddle of the IPG20 can be cut down to suit the specic
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 an appropriate
distance, subject to the expected ow, into the pipe when the controller is
installed in the pipework. If it is necessary to shorten the trailing wire it must
be tig welded to avoid fraying. If you are unsure as to what length the
paddle should be, a paddle trimming calculator is available at :
http://www.kelco.co.nz/paddle-trimming-calculator.php
If you know what the expected ow 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 and trailing wires to suit the IPG20 pump controller are available
from Kelco or from your distributor.
Apply sealing compound or Teon tape to the process connection thread
on the controller and screw the controller into the pipework using the
spanner ats on the process connection. Do not screw the controller into
the pipework by twisting the electrical housing. The controller can be
permanently damaged by twisting the electrical housing. 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 IPG20. The controller must be
square to the axis of the pipework with the direction of ow arrow pointing
in the direction of ow.
DETACHING THE ELECTRICAL HOUSING
WARNING: Always switch o󰀨 the power and 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
the IPG20 can be detached from the paddle assembly. Removing the
electrical 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 o󰀨, do not twist it when doing this. Once the
electrical housing has been removed, the paddle assembly can be

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unscrewed from the pipework using the spanner ats on the body of the
paddle housing. Simply reverse this procedure to ret the electrical housing
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 IPG20 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 anti-clockwise (outward) the force against the paddle that resists
ow will be reduced. The paddle will become increasingly more sensitive
and will respond to progressively lower ows 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 o󰀨 position when ow stops.
The range of sensitivity adjustment will also be a󰀨ected by the orientation
of the controller. In horizontal pipework with the IPG20 mounted vertically
the useable range of adjustment is approximately 8 turns. In vertical
pipework with the IPG20 installed horizontally the full 10 turn range can be
utilised.