KELCO IPG20 MK3 Assembly instructions

Engineering Pty Ltd
Sydney Australia
KELCO IPG20 MK3
www.kelco.com.au
KELCO
INSTALLATION &
PROGRAMMING MANUAL
INTELLIGENT PUMP GUARD

The IPG20 MK3 is an industrial control device. It is specifically 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 qualified 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.
VERY IMPORTANT SAFETY NOTICE
PLEASE READ THIS BEFORE INSTALLING THIS CONTROLLER
2

The IPG20 MK3 intelligent pump guard is a pressure and flow based device
that “learns” the operating pressure each time the system is started. This
allows for finely targeted parametres where any significant variation in the
operating pressure or loss of flow 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 different hydrant or hydrant group, or even a different 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 verified 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.
fixed sprinklers, stationary irrigator or irrigator on flat 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.
Vibration will damage the
electronics within the IPG20 and will void your product warranty.
IMPORTANT: READ THIS FIRST
OVERVIEW
DO NOT EXPOSE THE IPG20 MK3 TO VIBRATION. INSTALL ONLY IN
PIPEWORK THAT DOES NOT VIBRATE.
3

The IPG20 is controlled and configured using 4 onboard buttons.
(R) Reset button: Stops the pump and restarts the IPG20 when released.
(^) Up arrow button: For increasing program settings.
(v) Down arrow button: For decreasing program settings.
(P) Programming button: For stepping through the menu and entering
settings into memory.
The IPG20 monitors its internal temperature when running. Pressing the (v)
button while the controller is powered up displays the current internal
temperature of the IPG20.
The LCD backlight can be turned on or off.
To turn the light off press and hold down the (v) button. Press and release
the (R) button. Release the (v) button. Repeat to turn the light on. The light
remembers the state it was last left in if power is turned off. The light can be
left permanently on or off as required.
When the IPG20 is powered up, pressing the (P) button, holding it down for
1 second and releasing it takes you to the top of the menu.
The IPG20 includes 4 multicolour lights to indicate activity;
Flow: This light is GREEN when the IPG20 detects flow and RED when no
flow 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 off when
the remote is open. The light is RED when remote input No. 2 is closed and
off when the remote is open. This light is PURPLE when both remote inputs 1
& 2 are closed.
THE LIGHTS
THE BUTTONS
TEMPERATURE
LCD SCREEN BACKLIGHT
PRESS (and release) THE (P) BUTTON
4

LOCATION
Install this controller in a location that is sheltered from direct exposure to
the weather whenever possible.
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 off. 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 metres 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.
5

The IPG20 is weatherproof and can be 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
diametres 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
flow must be in an upward direction. Do not install this controller on the
underside of horizontal pipework.
Never install the IPG20 in the suction pipe of the pump or
in any location where it may be subject to partial vacuum conditions.
WARNING:
6

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 first and the electrical housing should then be fitted
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 flat
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 flat 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 flat of your hand on the top face of the lid of the electrical
enclosure. While pressing down, screw the M4 locking 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 locking 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 fit
the paddle assembly into the pipework use a suitable spanner and the
spanner flats 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 flow must be in an upward direction past the
controller’s paddle. The IPG20 is supplied with a 1” BSP process
connection. A matching female threaded socket or pipe tee must be
provided to fit 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.
INSTALLATION
7

A pressure relief valve should be fitted to any system that can exceed the
pressure rating of any component on that system. Alternately, always
confirm that the pressure safety limits of individual items are compatible and
not compromised without the fitting of appropriate safety devices, i.e. a
Pressure Relief Valve (PRV).
IMPORTANT SAFETY NOTE :
8

If you know what the expected flow rate is the calculator allows you to enter
your pipe diametre 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 Teflon tape to the process connection thread
on the controller and screw the controller into the pipework using the
spanner flats 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 flow arrow pointing
in the direction of flow.
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 off, do not twist it when doing
this.
The polypropylene paddle of the IPG20 can be cut down to suit the specific
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 flow, 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 :
TRIMMING THE PADDLE
https://www.kelco.com.au/paddle-trimming-calculator/
DETACHING THE ELECTRICAL HOUSING
WARNING: Always switch off the power and de-pressurise the pipe
system before attempting to remove the electrical housing.
9

Once the electrical housing has been removed, the paddle assembly can
be unscrewed from the pipework using the spanner flats on the body of the
paddle housing. Simply reverse this procedure to refit 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.
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
flow will be reduced. The paddle will become increasingly more sensitive
and will respond to progressively lower flows 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 off position when flow stops.
The range of sensitivity adjustment will also be affected 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.
SENSITIVITY ADJUSTMENT
10

A means for disconnection of the IPG20 must be incorporated in the fixed
wiring in accordance with the wiring rules.
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 specific 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.
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.
ELECTRICAL INSTALLATION
IMPORTANT
INTRODUCTION
All electrical work associated with the IPG20
must be carried out by qualified electrical
personnel and all electrical work must conform
to AS/NZ standards and to local wiring rules.
WARNING
11

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 effect 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 effectively 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 and
the Normally Open terminal of Relay 1.
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
12

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.
The IPG20 has 3 X M20 cable glands. As supplied, the cable glands are
blanked off. The cable glands can accept cable from 7 to 9mm diametre.
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 flat 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.
CABLES
BROWNOUT OR BLACKOUT
13
Rubber Plug
M20 Gland Nut
Backing Washer
Plug unused cable
glands using the
rubber plugs
(supplied). Fully
tighten the gland nut to
seal the unused cable
port.
Rubber Grommet
Controller Housing
Backing Washer
Cable 7mm to 9mm diametre
Crimp the ears of the
strain relief ring onto
the cable and pull the
cable back into the
slots in the gland
housing.

16A at 240VAC
10A at 240VDC
50mA at 5VDC
Maximum Supply Voltage
Minimum Supply Voltage
Maximum Supply Voltage
Minimum Supply Voltage
With Both Relays Closed
With One Relay Closed
Quiescent State (relays open)
260VAC 50/60Hz
110VAC 50/60Hz
25VAC or 25VDC
18VAC or 18VDC
Resistive Load
Motor Load (P1) 2.4kW
Minimum Load
68mA Max at 24VDC 1.63W
52mA Max at 24VDC 1.25W
25mA Max at 24VDC 0.60W
The IPG20 MK3 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.
RELAYS
CONTACT RATINGS FOR RELAY 1
SUPPLY VOLTAGE LIMITATIONS
VOLTAGE LIMITS ON TERMINALS LV & N
POWERING THE IPG20
14
VOLTAGE LIMITS ON TERMINALS A & N
POWER REQUIRED TO DRIVE THE IPG20

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.
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 off.
The remote switch can be installed some distance from the IPG20. The
maximum distance is limited by cable resistance and capacitance.
A remote momentary on switch with voltage free contacts can be connected
to remote input 2 and used to reboot the IPG20. In effect 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.
Never connect an external power source of any kind to the
IPG20’s remote input terminal.
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.
WARNING:
WARNING:
RMT2 REMOTE RESET
REMOTE INPUTS
15

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
diametres.
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 metres). 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 sufficient 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.
16

Pump Motor 1
110 ~ 240VAC 50/60Hz Pump Motor 2.4kW
Max. when the HD terminal is linked
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
Remote switches with
NO or NC voltage free contacts
Supply
110 ~ 240VAC 50/60Hz.
Active
Neutral
Audible or Visual Alarm
PLUG & PLAY CONNECTIONS
CONNECTIONS FOR A SINGLE PHASE PUMP
Earth
Link
Optional voltage
free external input
All electrical wiring associated with this
controller must be carried our by a
qualified electrician
WIRING DIAGRAMS
17

LOW VOLTAGE SUPPLY
DUAL SINGLE PHASE PUMPS & 2 REMOTE INPUTS
Pump Motor 1
110 ~ 240VAC 50 Pump Motor 2.4kW Max.
when the HD terminal is linked
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
Remote switches with
NO or NC voltage free contacts
Supply
110 ~ 240VAC 50
Active
Neutral
Pump Motor 2
Single Phase 110 ~ 240VAC Motor 3A
Max. when controlled directly
Positive
Negative
Supply
18 to 24 Volts AC or DC
18

3 Phase Pump Motor
Contactor
WARNING
Contactor coil rating must not
exceed 240VAC
N
L1
L2
L3
3 Phase Pump Motor 2
3 Phase Pump Motor 1
Contactor 2
Contactor 1
WARNING
Contactor coil rating must not
exceed 240VAC
N
L1
L2
L3
DUAL 3 PHASE PUMP CONTROL
BASIC 3 PHASE PUMP CONTROL
19

3 Phase Pump Motor
Alarm
16A 240V Maximum
resistive load
Contactor
WARNING
Contactor coil rating must not
exceed 240VAC
N
L1
L2
L3
Remote switch
with NO or NC
voltage free contacts
3 PHASE PUMP WITH ALARM AND REMOTE SWITCH
MP WITH 24V CONTROL CIRCUIT & SOLENOID VALVE
3 Phase Pump Motor
Solenoid Valve
Contactor
WARNING
Contactor coil rating must not
exceed 240VAC
24VAC
Transformer N
L1
L2
L3
Remote switch
20