Kelco E30 Installation manual

KELCO E30

DIGITAL PRESSURE SWITCH

PROGRAMMING INSTRUCTIONS

KELCO Engineering Pty Ltd

Sydney Australia

www.kelco.com.au

Table Of Contents

Please Read Me First

The E30 digital pressure switch is supplied pre-loaded with a simple program. It

is set to mode 1, loss of prime pressure switch, and it has its startup and run-on

timers both set to 5 seconds. All other functions are turned off and its pressure

set points are all set to zero.

Provided the E30 is unlocked you can restore it to this default state at any time by

pressing and holding down the (P) button and pressing the (R) reset button at the

same time. Release the reset button while still holding down the (P) button and

then release the (P) button. This process is called purging the system and doing

this removes any settings you have entered and restores the E30 to its original

default state.

Introduction................................................................................................... 1

E30 Modes and Functions............................................................................ 2

Operating Range........................................................................................... 3

Programming the E30.................................................................................

The Three Operating Modes.......................................................................

Mode 1 Pressure Switch.............................................................................

Mode 2 Pressure Guard..............................................................................

Mode 1 In Detail...........................................................................................

Mode 2 In Detail...........................................................................................

Mode 3 In Detail...........................................................................................

LCD Screen Back Light...............................................................................

Program Lock..............................................................................................

Alarm Relay in Detail.................................................................................... 18

Introduction

The E30 digital pressure switch is a multifunction digitally programmable pressure

switch that can be set up to function as a conventional differential pressure switch,

a loss of prime pressure switch, an over and under pressure protection device (a

pressure guard) or as a digital snap action pressure switch with normally open or

normally closed contacts and an adjustable differential.

The way the E30 functions is selected using the pressure switch’s simple menu

structure. The switch functions are divided into three modes. Mode 1 sets the

E30 up as a loss of prime pressure switch and by leaving its trip pressure set to

zero, a conventional differential pressure switch. Mode 2 sets it up as a pressure

guard and mode 3 emulates the function of a mechanical snap action single

pressure point pressure switch.

The actual selection of a suitable mode of operation is beyond the scope of this

book as it is related to the system requirements and the specic control the system

requires. A specic mode must be selected prior to programming the E30 and

that selection will depend on what level of control is required. In order to achieve

the best performance from the E30, observe the following basic points.

1) Use the least number of functions possible. Do not program in functions you

do not specically require as to do so will make the system’s operation

unnecessarily complicated and may produce unexpected interactions between

the various functions.

2) When moving from mode to mode and from function to function always reset

time and pressure values back to zero before moving on. Do not leave timers or

pressures set up with some value entered and subsequently decide not to use

that specic function. If you do this then enter zero values or purge the system

before exiting the unrequired function. Provided the E30 is unlocked, a quick way

to reset and clear out any unwanted settings is to press and hold down the (P)

button while also pressing the (R) reset button. This is called purging the system

and doing this clears all the user settings out of the E30 and restores it to its

original default state.

3) Set realistic and sensible values into the various functions. For example, do

not try to set a pump to stop at a lower pressure than you set it to start at. Always

set the E30’s starting and stopping pressures to as wide a difference as possible.

MODE 1 2 3

Functions (# User Settable)

# Selectable pressure units kPa or psi Y Y Y

# Start-up timer, fully adjustable and self terminating Y Y Y

# Run-on timer, fully adjustable and self terminating Y Y Y

# Delayed re-starting timer, once stopped delays the restart Y

# Batch control, sets a specic run time for the pump Y

# Auto restart if run dry, both single and multiple attempts Y

# Trip pressure, fully adjustable and can be turned on or off Y Y

# Snap pressure, allows the setting of a single switch point Y

# Snap pressure switching differential (delta pressure) Y

# Starting pressure, fully adjustable and can be turned off Y Y

# Stopping pressure, fully adjustable and can be turned off Y Y

# Anti-cycling controls the number of motor starts per hour Y Y

# Anti-cycling sensitivity control to avoid nuisance tripping Y

# Start the pump at a preset low pressure Y Y Y

# Stop the pump at a preset high pressure Y Y Y

# User can congure the E30’s output to be relay 1 or relay 2 Y

# User can congure the E30’s output relay to be NO or NC Y

# Start & stop a pump using an external low voltage switch Y Y Y

Displays the system’s pressure in preferred units, kPa or psi Y Y Y

Displays the high & low pressure set points in preferred units Y Y

Displays the snap pressure point in preferred units Y

Displays a warning if you enter incorrect pressure settings Y Y

Displays the reasons for faults and alarms on its LCD screen Y Y Y

Over pressure alarm automatically invoked at 22 Bars Y Y Y

# Alarm relay can be set to close on 1 of 7 specic conditions Y Y Y

E30 Modes and Functions

Operating Range

Ambient temperature range 1ºC to 50ºC

Liquid temperature range 1ºC to 60ºC

Ingress protection rating IP67

Start-up timer Adjustable from 1 second to 4 minutes

in 1 second increments.

Run-on timer Adjustable from 1 second to 15 minutes

in 1 second increments.

Batch controller Adjustable from 1 minute to 99 Hours

59 minutes in 1 minute increments.

Delayed restarting Adjustable from 1 minute to 99 Hours

59 minutes in 1 minute increments.

Anti-cycling Adjustable from 1 motor start per hour

to 1800 starts per hour.

Anti-cycling sensitivity adjustment Adjustable from 2 to 50 sequential starts

Run dry auto restart settable to single or

repeated attempts

Adjustable from 1 minute to 99 Hours 59

minutes in 1 minute increments.

Maximum operating pressure static

or dynamic 20 Bars 290 psi

Minimum operating pressure static or

dyamic

1 Bar absolute or 14.7 psi absolute 0 kPa

gauge or 0 psi gauge.

Minimum burst pressure, all models > 30 Bars 435 psi

Trip pressure range Adjustable from 0 to 2000 kPa or 0 to 290

psi in increments of 1 kPa or 1 psi

Snap pressure range, mode 3 only Adjustable from 1 to 2000 kPa or 1 to 290

psi in increments of 1 kPa or 1 psi

Snap pressure differential, mode 3 only Adjustable from 7 to 140 kPa or 1 to 20 psi

in increments of 7 kPa or 1 psi

Starting pressure range Adjustable from 0 to 2000 kPa or 0 to 290

psi in increments of 1 kPa or 1 psi

Stopping pressure range Adjustable from 0 to 2000 kPa or 0 to 290

psi in increments of 1 kPa or 1 psi

Minimum pressure differential on to off or

off to on, modes 1 and 2 only

1 kPa or 1 psi. Practical limit is nominally 7

kPa or 1 psi

Automatic over pressure shut down Fixed setting 2200 kPa 22 Bars 430 psi

Important: The E30 must not be used in negative pressure or partial vacuum applications.

It must only ever be used in positive pressure systems.

Programming the E30

The E30 is fully programmable. It accepts input via 4 push buttons. The buttons

are marked (P) for programming, Up and Down for data entry and a reset button

(R). Pressing the (P) button during normal operation stops the pump and allows

entry to the E30’s menu, provided the pressure switch is unlocked. Subsequent

pressing of the (P) button steps you through the menu from one option to the next.

Each option can be adjusted using the up and down buttons.

Pressing the (P) button stores the settings you make into the E30’s memory and

steps you to the next option. When you reach the end of the options list the menu

asks you to press the (R) reset button to conrm your settings and to resume

normal running. You can automatically save any changes you have made and

exit out of the menu at any time by simply pressing the reset button. The settings

you make are non-volatile and are recorded into the E30’s memory . Your settings

will not be lost if the pressure switch is switched off for extended periods. When

power resumes the E30 is switched back on and the E30 will automatically boot

up and resume running using the settings you recorded in its memory.

The Three Operating Modes

The E30 can be set to operate in one of three fundamental modes. An initial

choice must be made as to how you want to control the pump. Once you have

made your choice the E30’s menu will ask you a series of questions that relate to

the specic mode you have chosen.

Mode 1 Pressure Switch

In mode 1 the E30 operates as a differential loss of prime pressure switch. Mode

1 provides you with a start-up timer to allow time for the pump to start and for the

system pressure to climb above whatever trip pressure you may enter. A run-on

timer is also available so the E30 can ignore short term dips in pressure without

tripping out on low pressure. In addition, delayed restarting is available as is anti-

cycling, batch running and automatic run dry restarting.

In mode 1 the E30 can be used to control a pump and to give it dry run protection

in the event of loss of pressure. Conventional pressure switches will continue to

run a pump if pressure is lost. This invariably damages the pump. In addition to

the high pressure cut-out and low pressure cut-in settings found in conventional

pressure switches the E30 included a third set point called the “trip pressure”.

The trip pressure can be set to some value that is less than the pressure switch’s

normal switch on pressure. In the event of the system’s pressure falling below the

trip pressure the run-on timer is invoked. The run-on timer can be set to ignore

the state of the pressure for a period of 1 second to 900 seconds (15 minutes). If

the system pressure recovers and rises above the trip pressure before the end of

the run-on time the E30 immediately reverts to normal operation. If at the end of

the run-on the pressure has not recovered and remains lower than the set trip

pressure then the E30 will shut down the pump.

The advantage of this system over a conventional mechanical loss of prime

pressure switch is that the E30 can tolerate dips in pressure for short periods

without tripping out and stopping the pump. Often momentary dips in pressure

occur when valves open in irrigation systems. The E30 is able to ignore these

pressure uctuations while still providing loss of pressure protection when a

genuine problem occurs.

If you leave the trip pressure set to zero the E30 reverts to operating like a

conventional pressure switch with no loss of pressure protection.

Mode 2 Pressure Guard

If you choose to use the E30 in mode 2 the pressure switch will function as a

pressure guard. The pressure guard allows you to set a starting and stopping

pressure and a trip pressure. In addition, a start-up timer and a run-on timer are

included. The pressure guard functions as a protection device for systems that

are normally controlled by other means. For example, a variable speed drive that

is fully controlled by a 4 to 20mA pressure transmitter may benet from the

inclusion of an E30 operating as a pressure guard. In the event of a problem

developing with the VS drive or with its pressure transmitter, the E30 is able to

override the system and shut the pump down if the pressure rises above or falls

below settable limits. The E30’s run-on timer facilitates momentary dips in

pressure without invoking the pressure guard’s loss of pressure protection and

the E30’s start-up timer allows time for the system to pressurise before the

pressure protection functions commence.

Mode 3 Snap Action Pressure Switch

In mode 3 the E30 functions as a single point pressure snap action switch. Either

of the pressure switch’s two output relays can be congured as the snap action

output and the output relay can be congured to have normally open or normally

closed contacts. The state of the output will change as the system pressure

passes through your set snap pressure. The hysteresis of the E30 operating in

mode 3 can also be adjusted from within the user program. The E30 is a solid

state device so unlike a mechanical pressure switch the hysteresis is determined

solely by the pressure units you choose to use.

Mode 1 In Detail

When set to mode 1 the E30 functions as a loss of prime pressure switch. The

user menu allows you to select your preferred pressure units in either kPa or psi.

Once you make your selection the units you have chosen will be displayed on the

LCD screen in all relevant phases of operation.

Mode 1 Remote Input

In mode 1 you can select to use a remote input switch to trigger the starting and

stopping of the pump. If you select to use the remote input the E30 will only allow

the pump to run while ever the remote switch is closed. The remote switch would

normally be a two position level switch in a remote tank or the contacts of a relay

in an external controller.

Mode 1 Start-up Timer

The E30 includes a start-up timer. The purpose of the start-up timer is to ignore

any initial lack of pressure and allow time for the system pressure to rise above

your set trip pressure before imposing any pressure limits on the pump’s operation.

The start-up timer can be adjusted from 1 second to 240 seconds (4 minutes) in

increments of 1 second. The time you set on the start-up timer will depend on the

system. In a bore pump application with a self-draining riser it may take a

considerable time for the line pressure to rise to any appreciable degree, while a

pressure system that is fully primed may only require one or two seconds to

establish pressure.

The start-up timer automatically terminates its run as soon as a pressure higher

than the set starting pressure is detected. You may have set the start-up timer to

30 seconds. If pressure above your set starting pressure is detected by the E30

in 5 seconds then the start-up timer will terminate its run in 5 seconds and revert

to normal running.

The start-up timer is initially set to 5 seconds by default. If you purge the E30

program the start-up timer will be reset back to its default 5 seconds.

Mode 1 Run-on Timer

The E30 includes a run-on timer that can be set from 1 second to 900 seconds

(15 minutes) in increments of 1 second. The purpose of the run-on timer is to

allow the E30 time to tolerate momentary dips in pressure that would otherwise

cause the shutdown of the pump. You can choose not to use the run-on timer by

setting its time to zero. If you do this then the instant the E30 detects a pressure

less than its trip pressure the pump will be shut down. In applications where

motorised valves are opening or long runs of pipe take time to pressurise the run-

on timers ability to tolerate system pressures that are less than the normal running

pressure is an invaluable feature.

The run-on timer is initially set to 5 seconds by default. If you purge the E30

program the run-on timer will be reset back to its default 5 seconds.

Delayed Restart

The E30 includes a function called delayed restart. If you choose to use this

function and press (P) you will be asked for a delay time in hours and then in

minutes. The range of adjustment is 1 minute to 99 hours 59 minutes in increments

of 1 minute.

The purpose of the delayed restart is to prevent the pump from restarting once it

has stopped on high pressure. As an example, if the pump system was being

used to ll a tank that had a oat valve tted to it and the valve closed then the

system pressure would rise and the E30 would shut the pump down once the

pressure reached your high pressure cut-out point. Ordinarily, if the oat leaked

or opened, the pressure would fall and the E30 would start the pump as soon as

the pressure reached your set cut-in pressure. The delayed restart function can

be used in such a situation to delay the restarting of the pump. The delay may be

to prevent the pump from hunting on and off in the leaking valve scenario or it may

be to allow time for the water level in the tank to drop some distance before

allowing the pump to restart.

At the end of the delay period the E30 will only allow the pump to start if the

pressure has fallen to below the set start pressure. If, after the delay the pressure

remains above your set starting pressure the E30 will prevent the pump from

starting until the pressure drops to the preset starting pressure.

Auto Restart

If the system pressure falls to below your set trip pressure, the E30 runs its run-on

timer and if no pressure is detected by the end of the run-on period the E30 will

shut the pump down. This is based on the assumption the pump has run dry. In

such a situation the auto restart function can be used to have the pump wait for

some set period of time and then attempt to restart the pump. The range of

adjustment is 1 minute to 99 hours 59 minutes in increments of 1 minute.

If you choose to use the auto restart and press (P) you will be asked if you require

single or repeated restarting. If you choose single restart the E30 will attempt to

restart the pump after your set delay period. If it fails to start the pump because

no pressure rise is detected within the E30’s set start-up time or if it successfully

starts the pump and subsequently runs dry again the E30 will then go into

permanent alarm. It will shut the pump down, close its relay contacts and display

a message on its LCD screen to indicate the pump has run dry.

If you choose to set the auto restart to repeated restart then each time the E30

detects a loss of pressure situation it will shut the pump down, wait for your set

restart delay period and then attempt to restart the pump. Each time loss of

pressure is detected the E30 will repeat this process. The auto restart function

can be used to cyclically pump down low yield bores and to have the pump shut

down and wait for a set period for the standing water level to recover before

automatically restarting the pump and repeating the process.

Batch Control

If you choose to use auto restart as described above, the E30’s batch controller

will not appear in the menu. To use the batch controller you must rst have set

auto restart to off. The batch controller and auto restart functions conict so the

E30’s menu prevents you from selecting both functions.

If you choose to use the batch controller and press (P) you will be asked for a

batch running time in hours and then in minutes. The range of adjustment is 1

minute to 99 hours 59 minutes in increments of 1 minute.

The batch controller allows you to have the pump run for a set period of time and

then automatically shut down. An example of its use would be to pump X hours

of water to a tank and then have the pump shut down. Pressing the reset button

on the E30 will then repeat this process.

If pressure rises to above the E30’s set high pressure cut-out point while the batch

is running the E30 will shut the pump down on high pressure and wait for the

pressure to fall to whatever you have set the starting pressure to. When the pump

restarts the batch controller will restart its run from 1 minute less than where it left

off. If you choose to use delayed restarting in conjunction with the batch controller

then the batch run will resume from 1 minute less than where it stopped at as

soon as the delayed restart period ends.

If pressure is lost when batch running and delayed restart is not used the E30 will

time out on its run-on timer and then shut the pump down and go into dry run

alarm. Batch running will only then recommence once you press reset or reset

the power to the E30. No knowledge will be retained as to where in its batch run

it was when ow was lost. The batch run in this situation will recommence from

the beginning of the set time.

Mode 1 Trip Pressure

The trip pressure can be set to any value from zero to 2000 kPa or from zero to

290 psi depending on the pressure units you have chosen to use. The trip

pressure must be set to some value that is less than the start pressure. If the

system pressure falls to below your set trip pressure during normal operation, it is

the set trip point that invokes the run-on timer and ultimately shuts the pump down

if pressure fails to rise above the trip pressure by the end of the run-on period.

The trip pressure can be set to 1 kPa or 1 psi less than your start pressure or it

can be set substantially less than the start pressure.

If you choose not to use the trip pressure and leave it set to zero then the E30

reverts to operating like a basic pressure switch. Its contacts will remain closed

at all pressures that are less than your set high pressure cut-out. If no pressure

is present in the system the contacts of the E30 will be closed. No loss of pressure

protection will be provided by the E30 if it is set up this way.

The trip pressure can be set as low as 1 kPa or 1 psi and it will provide loss of

pressure protection to a pumping system but it is important to remember that if it

is set to zero no low pressure protection will be provided by the E30.

Mode 1 Start Pressure

The start pressure can be set to any value from 1 kPa to 2000 kPa or from 1 psi

to 290 psi in increments of 1 kPa or 1 psi. Normally the start pressure would be

set to the pressure at which you want the pump to start. In normal operation each

time pressure drops to whatever value you have set, the pump will start. Once

running the pressure can fall to below the value you have set and the pump will

continue to run. In fact if you have not set the trip pressure to some value greater

than zero, the pump will continue to run in spite of a complete lack of pressure.

The start pressure can be set as low as 1 kPa or 1 psi and the E30 will function in

the manner described above. If you choose to set the start pressure to zero you

will invoke a warning message from the E30 to check your pressure settings. The

E30 will not tolerate having its start pressure set to zero. The start pressure must

always be set to a higher pressure than the trip pressure. If you have set the trip

pressure to zero and you also set the start pressure to zero then both pressures

would be the same and the E30 will not tolerate this and will display a message

telling you to check your pressure settings.

Mode 1 Stop Pressure

The stop pressure is the pressure at which the E30 will shut down the pump in

normal operation. It must be set to some value that is higher than start and trip

pressures. The range of adjustment is zero to 2000 kPa or zero to 290 psi in

increments of 1 kPa or 1 psi. If you attempt to set the stop pressure to a value

that is less than the start or trip pressures you will invoke a warning message from

the E30 to check your pressure settings.

The stop pressure can be set to a minimum of 1 kPa or 1 psi higher than the start

pressure and the E30 will function. Normally you would set the difference between

the starting and stopping pressures to some value that is much greater but for

some special applications the close operating differential capability of the E30 is

an invaluable feature and can be used in some circumstances as an alternative

to the single point snap action pressure switch described in mode 3.

Mode 1 Anti-Cycling

Electric motors are often limited in the number of times they can be safely started

in an hour. This is particularly important in the operation of submersible bore

pumps. When a motor starts there is an initial inrush of current that produces

heat in the coils and iron rotor of the motor. If the frequency of starts is excessive

the accumulation of heat within the motor can cause severe damage and eventual

failure of the motor. Submersible bore pump motors are particularly prone to

damage from excessive cycling (starting and stopping).

The anti-cycling option built into the E30 allows the user to set the maximum

number of times the pump can be safely started in any one hour period. If you

select yes to this option the screen that follows will ask you to enter the maximum

number of times the pump can be started in any one hour. The number of starts

can be set from 1 start per hour to 1800 starts per hour. Please contact your

pump supplier to obtain the correct gure for your specic pump. In operation the

anti-cycling system monitors both time and the number of starts and compares

the two. If the starts per hour rate is exceeded by a settable number of consecutive

starts in any one hour period the pump will be automatically shut down and the

E30 will display a message indicating the starts per hour rate was exceeded.

The anti-cycling function can be adjusted in terms of its sensitivity to repeated

rapid restarts. The E30’s menu asks you for a sensitivity number. The range is 2

to 50 restarts in sequence at a time interval that is less than the number of starts

per hour you have entered. The default value is 10. You can make the E30 more

sensitive to rapid cycling by decreasing this number or less sensitive by increasing

this value.

As an example, consider a pump set to a sensitivity value of 10 and also set to

360 starts per hour, one start every 10 seconds maximum. If the pump starts 9

times in a row at less than 10 seconds between starts and then does not start

again for 12 seconds the anti-cycling alarm will not be invoked. If however, the

pump were to start 10 times in a row at less than 10 seconds between starts, on

the eleventh start the anti-cycling system would be invoked and the pump would

be shut down. In the same situation, if the sensitivity setting was 2 rather than

10 then the anti-cycling alarm would be invoked after only 2 consecutive starts at

less than 10 seconds between each start, making it 5 times less tolerant of rapid

cycling that it previously was.

In a conventional pressure system the anti-cycling function can be used to protect

the pump from damage in the event of the system’s air cell losing its air charge.

If air is lost from a system’s air cell due to a ruptured diaphragm or leaking air

valve, the pump will hunt on and off rapidly. Such rapid cycling will cause the

pump to overheat very quickly. The E30’s anti cycling feature can be used to shut

down the pump and prevent damage in such a situation. To use the anti-cycling

function for this type of pump protection simply set the starts per hour to some

value that is marginally higher than the system’s normal start rate. This will avoid

nuisance tripping but will shut the pump down if excessive sequential cycling is

encountered.

Mode 2 In Detail

When set to mode 2 the E30 functions as a pressure guard. The pressure guard

is a protection device for protecting a pump system from pressure extremes, both

high and low. Its normal application is not to control the pump but to provide

pressure protection should the system’s normal control fail. Consider a multistage

centrifugal pump or a helical rotor pump discharging into low grade Poly pipe. If

the pump’s normal pressure control fails and the pressure rises uncontrollably,

the E30 in pressure guard mode can be set to trip out and stop the pump thus

preventing the pipe system from bursting. If you choose to use the E30 in pressure

guard mode and press (P) you will be asked a series of questions that will lead

you through the conguration process.

Select Pressure Units

The rst question the E30 asks is what pressure units you want to work in, kPa or

psi. The units you choose will be used in all appropriate displays throughout the

E30 once you make your choice.

Mode 2 Remote Input

If you select to use the remote input function the E30 in pressure guard mode will

only operate while the remote input switch is closed. The remote switch can be a

two position level switch in a remote tank or the contacts of a relay in an external

controller.

Mode 2 Start-up Timer