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.
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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