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

5
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.

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ELECTRICAL INSTALLATION
IMPORTANT
A means for disconnection of the F60 must be incorporated in the xed
wiring in accordance with the wiring rules.
INTRODUCTION
The IPG20 is designed to directly control single-phase pump motors to
2.4kW. via its Relay 1. No interposing contactor is required for such
applications. The controller can also be used to control 3 phase pump
motors of any size via an appropriate interposing contactor.
WARNING: The contactor control circuit must never exceed 240VAC.
Never connect the IPG20 and contactor coil directly across 2 phases.
The IPG20 requires a stable 110V to 240V 50/60Hz supply when operated
from the mains. It can also be operated from an 18 to 24V AC or DC supply
by utilising the low voltage active terminal LV and neutral terminal N (see
the included wiring diagrams). When operated from a low voltage DC
supply the terminals LV and neutral N are not polarity sensitive. Pay
attention to cable sizes and ensure cables are adequate for the specic
pump motor load. This is particularly important where long cable runs are
to be used in the installation. If the voltage drop associated with the starting
of the pump motor is excessive the IPG20 may repeatedly reset and not
operate properly.
WARNING
All electrical work associated with the IPG20
must be carried out by qualied electrical
personnel and all electrical work must
conform to AS/NZ standards and to local
wiring rules.

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THE HD (Heavy Duty) TERMINAL
The IPG20 contains a solid-state switch (HD Heavy Duty drive) that can be
used to protect the contacts of Relay 1 by eliminating the destructive arcing
caused by the starting and stopping of motors. The solid-state switch is
accessible from the HD terminal on the terminal block. We recommend the
HD drive be used whenever the controller is used to directly control a single
phase motor. The HD drive should not be used when the IPG20 is
connected to a contactor, external timer, low wattage relay or to any other
external device where voltage free contacts are required. It is strictly
intended for the direct control of highly inductive AC motor loads. The HD
terminal and the controller’s built in relays must never be directly connected
to a DC motor under any circumstances. When the HD terminal is linked
to the normally open terminal of Relay 1, the HD drive in e󰀨ect parallels a
42 Amp solid state switch across the relay’s normally open contacts. This
increases the momentary current carrying capacity of the relay’s contacts
to well over 60 Amps. The solid-state HD drive is only activated for a brief
period when the motor starts and stops. It e󰀨ectively handles the high
inrush current associated with the motor starting, and it provides a current
path for the destructive back EMF associated with the motor stopping.
To use the HD drive, place a heavy link wire between the HD terminal
The HD terminal must be left unused or only ever linked to Relay
1 Normally Open. It must never be used for any other purpose
and it must never be connected to any external device. Under no
circumstances connect the HD terminal to the terminals of Relay
2. The HD terminal must be regarded as live at all times and at full
mains potential.
WARNING

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and the Normally Open terminal of Relay 1.
BROWNOUT OR BLACKOUT
If a blackout or brownout occurs the IPG20 will not retain any memory of
where in its run or stop cycle it may have been, it will simply shut down the
pump. When power resumes, the IPG20 will attempt to reboot, restart the
pump and run any timer settings from the beginning. If the power supply is
unstable a manual reboot can be done by pressing and releasing the
IPG20’s reset button.
CABLES
The IPG20 has 3 X M20 cable glands. As supplied, the cable glands are
blanked o󰀨. The cable glands can accept cable from 7 to 9mm diameter.
See sketch for assembling the cable gland components. The controller is
supplied with a set of steel crimp rings. The crimp rings are to provide
strain relief for the controller’s cables. To use the crimps, place one on the
cable approximately 3 to 4mm below the end of the cable’s outer sheathing.
Crimp the two ears of the ring at using bull nosed pliers. Pull the cable
back through the cable gland until the crimp ring’s ears are fully located
into the slots in the cable gland housing.
SUPPLY VOLTAGE LIMITATIONS
VOLTAGE LIMITS ON TERMINALS A & N
Maximum Supply Voltage 260VAC 50/60Hz
Minimum Supply Voltage 110VAC 50/60Hz
Rubber Plug
Backing Washer
M20 Gland Nut
Plug unused cable glands
using the rubber plugs
(supplied). Fully tighten
the gland nut to seal the
unused cable port.
Crimp the ears of the
strain relief ring onto the
cable and pull the cable
back into the slots in the
gland housing.
Cable 7mm to 9mm diameter
Controller Housing
Rubber Grommet Backing Washer
4mm

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RELAYS
The IPG20 Mk2 houses 2 relays. Relay 1 has S.P.D.T contacts. Relay 2
has S.P.S.T normally open contacts. Relay 1 is normally regarded as the
pump control relay and relay 2 is normally regarded as the alarm relay.
When operating the IPG20 as a dual pump controller, relay 2 is used to
control the second pump.
With the HD terminal linked to the NO terminal of Relay 1, the IPG20
can directly control a single phase motor up to 2.4kW.
Without the HD terminal link in place, relays 1 & 2 are limited to
directly controlling a motor to 0.75kW. Both relays can control
motors of any size via interposing contactors.
VOLTAGE LIMITS ON TERMINALS LV & N
Maximum Supply Voltage 25VAC or 25VDC
Minimum Supply Voltage 18VAC or 18VDC
POWER REQUIRED TO DRIVE THE IPG20
With Both Relays Closed 68mA Max at 24VDC 1.63W
With One Relay Closed 52mA Max at 24VDC 1.25W
Quiescent State (relays open) 25mA Max at 24VDC 0.60W
POWERING THE IPG20
CONTACT RATINGS FOR RELAY 1
16A at 240VAC Resistive Load
10A at 240VDC Motor Load (P1) 2.4kW
50mA at 5VDC Minimum Load

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IMPORTANT: When directly controlling a pump motor through relay 1,
always link the HD terminal to relay 1 Normally Open terminal and make
sure the maximum switched motor current never exceeds 10 Amps. On a
pump motor P1 must not exceed 2.4kW.
REMOTE INPUTS
WARNING: The low voltage source available at the LV terminal is non-
isolated and must be regarded as operating at full mains potential whenever
the IPG20 is powered from the mains. Relative to earth, the LV terminal is at
full mains potential.
RMT1 MANUAL START
A remote momentary on switch with voltage free contacts can be connected
to remote input 1 to start the learning process if fully automatic operation is
turned o󰀨.
RMT2 REMOTE RESET
A remote momentary on switch with voltage free contacts can be connected
to remote input 2 and used to reboot the IPG20. In e󰀨ect the remote switch
acts like the reset button on the IPG20 itself. It causes whatever process
is running to stop and for the controller to reboot. If the remote reset switch
remains closed the IPG20 displays the message RELEASE THE RESET
BUTTON. The IPG20 will not reboot until the remote reset button is
released.
The supply to the remote switches must be taken from the LV terminal of
the IPG20 when the controller is powered from the mains or from a 24VAC
source. The IPG20 must always be powered from the same source as the
supply to the remote switch. In all cases the remote switch return wire must
be connected to the Remote input RMT1 or RMT2 terminal on the IPG20.
The supply to the external switch will range from 12 - 24VDC or from 20 -
35VAC depending on the supply voltage.
WARNING: Never connect an external power source of any kind to
the IPG20’s remote input terminal.
The remote switch can be installed some distance from the IPG20. The

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maximum distance is limited by cable resistance and capacitance. The
total cable resistance must not exceed 5K Ohms with the remote switch
closed. The total capacitance of the cable must not exceed 25nF with the
remote switch open. Wires to the remote switch should be run separately
from power carrying cables. Do not run the remote switch wires in a conduit
that also contains power cables. Capacitive coupling between the adjacent
cables may cause false triggering of the IPG20’s remote input. For cable
runs longer than 150 metres we suggest using 2 separate wires to reduce
capacitive coupling between the adjacent wires. When set up this way
cable resistance becomes the limiting factor for distance. The following
table sets out the resistance of typical copper wire of various diameters.
Note: that the cable resistance refers to the total resistance out to the
remote switch and back, as measured at the controller across the 2 remote
connection wires with the external remote switch closed. Where the system
is switching zones the IPG20 can be triggered to repeat the learning
process to learn the pressure of the new zone.
If you select “use alarm relay” and then select “relay closed whenever
pump is stopped” (No. 2 Relay) that tells the controller you are going to use
valve sequencing. When you then get deeper into the menu and are asked
if you want to use cyclic running, if you enter “Yes” it asks you for the
running time, followed by the stopping time. After the stopping time a new
question pops up “learn the new pressure”. (It does not appear unless you
have previously selected to use the “alarm relay” and “closed when pump
is stopped”). That means it does not confuse users who don’t want valve
sequencing. By having such a question there it means a user can opt for
“No” and still use cyclic running along with an alarm relay that closes
whenever the pump is stopped. (In other words, NOT relearn the pressure).
As an example, a water tank is located 2000 metres from the IPG20. Two
separate wires each 0.2mm^2 are run to the remote tank (total wire length
is 4000 meters). The resistance as measured across the 2 wires back at
the IPG20 (with the tank level switch closed) is 382 Ohms. This is well
under the 5,000 Ohm limit. The remote input to the IPG20 will operate
properly provide the wires are separated by su󰀩cient distance that the
capacitance between them is less than 25nF. Capacitance should be
measured between the wires when the remote switch is open and it must
be less than 25nF.

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WIRING DIAGRAMS
PLUG & PLAY CONNECTIONS
CONNECTIONS FOR A SINGLE PHASE PUMP
PLUG AND LEAD WIRING
All electrical wiring associated with
this controller must be carried our by
a qualified electrician
Optional voltage free
external input
Earth Link
Control of a Single Phase Pump with an Alarm and two remote inputs
Remote switches with
NO or NC voltage free contacts
This link wire must be used whenever
the controller is directly controlling a single
phase pump motor, as shown. Do NOT use the
HD link in 3 phase or single phase control circuit
applications
Active
Pump Motor 1
110 ~ 240VAC 50/60Hz Pump Motor 2.4kW
Max. when the HD terminal is linked
Neutral
Supply
110 ~ 240VAC 50/60Hz.
Audible or Visual Alarm

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CONTROL OF A SINGLE PHASE PUMP MOTOR WITH A SECONDARY
BACK UP PUMP AND TWO REMOTE INPUT SWITCHES
Remote switches with
NO or NC voltage free contacts
This link wire must be used whenever
the controller is directly controlling a single
phase pump motor, as shown. Do NOT use the
HD link in 3 phase or single phase control circuit
applications
Pump Motor 2
Single Phase 110 ~ 240VAC Motor
0,75kW Max. when controlled directly
through relay 2, as shown.
Active
Pump Motor 1
110 ~ 240VAC 50/60Hz Pump Motor 2.4kW
Max. when the HD terminal is linked
Neutral
Supply
110 ~ 240VAC 50/60Hz.
DUAL SINGLE PHASE PUMPS & 2 REMOTE INPUTS
LOW VOLTAGE SUPPLY
Negative
Positive
Supply
18 to 24 Volts AC or DC

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BASIC THREE PHASE PUMP CONTROL
3 Phase Pump Motor
N
L3
L2
L1
Contactor
WARNING
Contactor coil rating must not
exceed 240VAC
BASIC 3 PHASE PUMP CONTROL
DUAL 3 PHASE PUMP CONTROL
DUAL 3 PHASE PUMP CONTROL
3 Phase Pump Motor 1
N
L3
L2
L1
3 Phase Pump Motor 2
WARNING
Contactor coil rating must not
exceed 240VAC
Contactor 1
Contactor 2

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3 PHASE PUMP WITH ALARM AND REMOTE SWITCH
THREE PHASE PUMP CONTROL WITH ALARM AND REMOTE INPUT
Remote switch
with NO or NC
voltage free contacts
Three Phase Pump Motor
Alarm
16A 240V Maximum
resistive load
N
L3
L2
L1
Contactor
WARNING
Contactor coil rating must not
exceed 240VAC
IPG20 24V WITH REMOTE AND LOW VOLTAGE SOLENOID VALVE
Remote switch
3 Phase Pump Motor
N
L3
L2
L1
WARNING
Contactor coil rating must not
exceed 240VAC
Contactor
Solenoid Valve
Transformer
24VAC
3 PHASE PUMP WITH 24V CONTROL CIRCUIT & SOLENOID VALVE