KELCO F29 Mk2 Assembly instructions

KELCO F29 Mk2
PROGRAMMABLE FLOW
SWITCH
INSTALLATION & PROGRAMMING
MANUAL
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au
Version 070218

2
IMPORTANT: READ THIS FIRST
DO NOT EXPOSE THE F29 Mk2 TO VIBRATION. INSTALL ONLY IN
PIPEWORK THAT DOES NOT VIBRATE. Vibration will damage the
electronics within the F29 and will void your product warranty.
This F29 programmable flow switch has been fully tested and calibrated. It
is set to operate in a basic way with most of its special functions and
features switched off. On start up the F29 will run the pump using its start
up timer for up to 5 seconds. If it finds flow in the first 5 seconds it will
continue to run the pump. If flow is lost, the pump will continue to run for 5
seconds held on by the F29’s built in run-on timer. If flow fails to return, the
pump will be shut down after the run-on period. Pressing and releasing the
(R) reset button on the F29 or resetting the power will repeat this basic
process.
THE BUTTONS
The F29 is controlled and configured using 4 onboard buttons.
(R) Reset button. Stops the pump and restarts the F29 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 F29 includes 4 multicolour lights to indicate activity.
Flow: This light is GREEN when the F29 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.

3
LCD SCREEN BACKLIGHT
The LCD backlight can be turned on or off.
To turn the light off 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 off. The light
can be left permanently on or off as required.
TEMPERATURE
The F29 monitors its internal temperature when running. Pressing the (˅)
button while the flow switch is powered up displays the current internal
temperature of the F29.
PRESS (and release) THE (P) BUTTON
When the F29 is powered up, pressing the (P) button, holding it down
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 F29’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 F29
1) Do not install the F29 in an exposed outdoor location. The F29 is
weatherproof, however, to ensure a long reliable life we recommend
it be protected from direct exposure to the sun and rain. A skull cap
is provided with the F29 and we recommend it be used to protect the
F29 when direct observation of the LCD screen is not required.
2 ) Do not expose the F29-S to freezing. If the F29 is to be used in
areas where freezing conditions will be encountered, use the stainless
steel F29-SS and always lag the pipework for several metres either
side of the flow switch to prevent the adjacent pipework from freezing.
3) Do not use the standard thermoplastic F29-S flow switch in hot
water applications. The standard F29-S is not designed to be used in
water hotter than 60ºC. The stainless steel model can be used in
water up to 90ºC.

4
4) Do not expose the thermoplastic F29-S to static or dynamic
pressures greater than 18 Bars, 261 psi. Do not expose the stainless
steel F29-SS to static or dynamic pressures greater than 200 Bars,
2900 psi.
5) Do not install the F29 in a section of pipe that is subject to vibration.
Vibration will cause premature failure of the electronic components
within the F29.
LOCATION
Where possible install the F29 in a location that is sheltered from direct
exposure to the weather. The F29 is weatherproof and is supplied with a
protective cover. However, to ensure a long reliable life we recommend it
be protected from direct exposure to the sun and rain. Intense sun light will
eventually cause discolouration and degradation of the flow switch’s
housing. It is therefore advisable to protect the F29 from the weather if
possible.

5
The F29 should be installed in a straight section of pipe preferably with 5
diameters of straight pipe either side of the paddle. The F29 can be
installed in a suitable pipe socket, tapping saddle or pipe tee.
The F29 can be installed in either the suction or discharge pipework of the
pump. It is more common to install it in the discharge pipe, either before or
after the system’s air cell. If the system includes an air cell a decision must
be made as to which side of the air cell to locate the flow switch. The way
the overall system functions will depend on this decision.
BEFORE THE AIR CELL
If the F29 is installed before the air cell, it will only start the pump on
pressure drop via an external pressure switch since the initial draw off will
be supplied from the air cell and will not push the paddle of the F29 into its
on position. The only change in state the flow switch will see will be the

6
Controller
Discharge
Controller installed before the air cell
closing of the external pressure switch’s contacts on a falling pressure.
Choose this arrangement if you want to keep pump starts to a minimum
and you are prepared to accept the delay in starting associated with the
slow pressure fall from the air cell.
AFTER THE AIR CELL
If you install the F29 in the pipework after the air cell the flow switch will
start the pump each time flow from the air cell pushes its paddle forward or
each time pressure falls to whatever pressure you have set the external
pressure switch to start at. Choose this arrangement if you want the system
to deliver a steady pressure and to start each time flow is sensed.

7
INSTALLATION
The F29 is supplied as two separate assemblies, the paddle assembly
and the electrical housing. The paddle assembly should be installed in the
pipework first.
TRIMMING THE PADDLE
The paddle of the F29 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 approximately half to
two thirds of the way across the pipe when the controller is screwed into
the pipework. If a low flow rate is expected through the system the paddle
should be cut longer, perhaps until it only clears the bottom of the pipe by 3
to 5mm. If you are unsure as to what length the paddle should be, a paddle
trimming calculator is available at: -
http://www.kelco.com.au/paddle-trimming-calculator-2
Discharge
Controller
Controller installed after the air cell

8
If you know what the expected flow 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 to suit the F29 Mk2 are available from Kelco or from your distributor.

9
FITTING THE PADDLE ASSEMBLY
To fit the paddle assembly into the pipework, apply Teflon tape or thread
sealing compound to the thread and use a suitable spanner and the
spanner flats provided on the paddle assembly (directly above the process
connection thread). Under no circumstances should the electrical housing
be twisted or used to screw the paddle assembly into the pipework or to
align the F29 with the axis of the pipework. To do so will irreparably damage
the F29 and void its warranty. 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 F29. The F29 can be installed in either vertical or horizontal
pipe. The F29 has a 1” BSP or NPT process connection. A matching
female threaded socket, pipe saddle or pipe tee must be provided to fit the
F29 into the pipework.
ATTACHING THE ELECTRICAL HOUSING
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.
The cap screw should be screwed fully through the hole provided on the
underside of the electrical housing and should be securely tightened using
a 3mm A/F Allen key (supplied).
DETACHING THE ELECTRICAL HOUSING
To allow easy access to the flow switch’s paddle, the electrical housing of
the F29 can be detached from the paddle assembly. Removing the
electrical housing allows access to the paddle without the need to disconnect
the electrical connections to the F29. To remove the electrical assembly,
switch off the system’s power and undo and completely remove the locking
screw (see diagram). Once the locking screw is removed, lift the electrical
housing straight off (do not twist it when doing this). 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 assembly. Simply
reverse this procedure to refit the electrical housing to the F29.
SENSITIVITY ADJUSTMENT
Under the end of the electrical housing on the F29 is a red hexagonal dust
cap. If you remove this dust cap you gain access to an adjustment screw

10
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 take a straight bladed screwdriver and 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 F29. In horizontal pipework with the F29 mounted vertically the
useable range of adjustment is approximately 8 turns. In vertical pipe with
flow upwards, the full 10 turn range can be utilised.
ELECTRICAL INSTALLATION
INTRODUCTION
When used with its HD terminal link in place, the F29 can directly control
single-phase pump motors to 2.4kW via its relay 1. No interposing contactor
is required for such applications. The F29 can also be used to control 3
phase pump motors of any size via an appropriate interposing contactor.
WARNING
All electrical work associated with the F29 must be
carried out by qualified electrical personnel and all
electrical work must conform to AS/NZ standards and to
local wiring rules.