KELCO F29 Installation manual

KELCO F29 PROGRAMMABLE
FLOW SWITCH
PROGRAMMING INSTRUCTIONS
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au
Version 010916

VERY IMPORTANT
This Kelco controller has been fully tested and calibrated. It is
presently unlocked and has a simple program loaded. It is set to
operate in a basic way with most of its special functions and features
switched o󰀨.
On start up this controller will run the pump using its start-up timer. If it
nds normal operating conditions in the pipe system it will continue to run
the pump. If pressure or ow conditions change the pump will continue to
run for a short period held on by the controller’s built in run-on timer. If
acceptable conditions fail to return the pump will be shut down after the
run-on time period. Pressing the red reset button on the controller’s lid or
resetting the power will repeat this basic process.
To change the functions of this controller please rst read the programming
book supplied with this unit.
IMPORTANT
DO NOT EXPOSE THIS CONTROLLER TO VIBRATION. INSTALL ONLY
IN PIPEWORK OR MANIFOLDS THAT DO NOT VIBRATE. Vibration will
damage the sensitive electronics within the controller and will void your
product warranty.

Table Of Contents
Introduction................................................................................................... 1
Programming the F29 Flow Switch & Basic Operation................................. 2
Alarm Relay.................................................................................................... 3
Start-Up & Run-On Timers............................................................................ 5
Advanced Functions, Reversing Relay1 Contacts........................................ 6
Pre-Start Delay Timer , Batch Control........................................................... 7
Batching with Additional Functions................................................................ 8
Delayed Restarting........................................................................................ 9
Cyclic Running............................................................................................... 10
Auto Restart................................................................................................... 11
Anti-Cycling................................................................................................... 12
Burst Pipe Detector........................................................................................ 13
Leak Detector................................................................................................ 15
Program Lock & Running Time Display......................................................... 16
The Hour Meter & LCD Screen Backlight....................................................... 17
Please Read Me First
The F29 ow switch is supplied unlocked and pre-loaded with a simple
program. It is set up with a 5 second start override time and a 5 second
run-on time. All other functions are turned o󰀨. With the default program
loaded, the F29 will start a pump in spite of an initial lack of ow, run the
pump for 5 seconds and expect to establish ow past its paddle within this
start up time. Given ow is established it will then run the pump continuously
while ow is present and it will shut the pump down if ow is interrupted for
more than 5 seconds or if ow stops completely.
You can restore the F29 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 (R) button and then release the (P) button. The timer
light will then ash rapidly red to indicate the process is complete. Doing
this removes any settings you may have entered and restores the F29 to
its original default state. You can then enter new settings or just press reset
(R) again and run the pump.
Page

1
Introduction
The F29 programmable ow switch includes a set of functions that can be
set up to control a pump. The functions range from a simple override on
start timer that allows a pump to start in spite of an initial lack of ow,
through to a range of sophisticated timing and ow based sequences. The
functions are independently accessible and adjustable through the F29’s
simple programming interface. The pages that follow set out what each
function does and how to set it up.
The actual selection of a suitable set of functions must be decided prior to
programming and will depend on what level of control the pumping system
requires. In order to achieve the best performance from this ow switch
observe the following basic rules.
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 introduce unpredictable interactions
that could cause the F29 to behave in a manner you had not anticipated.
2) The best way to switch o󰀨 a function that you have previously selected
and subsequently decided not to use is to purge the entire program and
restore it to its default state rather than simply switch the particular function
o󰀨. Purging the program ensures the functions are properly disabled and
their stored values are all set to zero or o󰀨. To purge the program press the
(P) button and the (R) reset button. Release the reset button while still
holding the (P) button down, then release the (P) button. The LCD screen
will display the message “Settings Cleared, Press (P) to Continue”. Press
(P) and then step through the program making your new selections as you
go.
3) Set realistic and sensible values into the various functions. For example,
do not set a pump to cycle on and o󰀨 rapidly. Always set the controller’s
running and stopping times to realistic values.

Programming The F29 Flow Switch
The F29 ow switch 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 ow switch’s menu.
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 ow
switch’s memory and steps you to the next option. When you reach the end
of the option list the ow switch asks you to accept the settings you have
made and to press the (P) button to resume normal running. You can
automatically save any changes you have made and exit out of the menu
at any stage during programming by simply pressing the (R) reset button.
The settings you make are non-volatile and are recorded in the ow switch’s
memory. Your setting will not be lost if the ow switch is switched o󰀨 for
extended periods. When the unit is switched back on the ow switch will
boot up and operate using the setting you recorded in its memory.
Basic Operation
Purging the F29 ow switch (pressing the (P) button and then pressing and
releasing the (R) reset button) automatically loads in a 5 second start-up
time and a 5 second run-on time. This is the factory default setting for the
F29 ow switch. All other functions will be turned o󰀨 or set to zero. If you
subsequently press the (P) button while the pump is running, the pump will
stop and the LCD screen will display the Kelco splash screen and the
controller’s model number. Pressing the (P) button several more times
steps you to the rst selection in the menu, the remote input selection
screen.
Remote Input
The remote input operates in one of two ways, remote start only or remote
start and stop. You choose which of the two you require by pressing the up
or down buttons and then conrming your selection by pressing the (P)
button. If you choose remote start only the F29 will start the pump each
time the remote switch closes its contacts. If the remote switch was a
pressure switch then its contacts would close on a falling pressure and that
2

3
could be used to start the pump. If you choose remote start and stop then
the pump will only operate while the remote switch is closed. An example
of its use would be for tank lling where the remote input was connected to
a tank level switch such as a Kelco D30.
Alarm Relay
After selecting yes or no to the remote input question and pressing (P) you
are asked if you want to use the alarm relay. The F29 contains a dedicated
relay (relay 2) with 16 Amp 240VAC rated voltage free contacts. The
contacts of the alarm relay can be used to control any required device
within its electrical rating including an external alarm or even a second
pump. The alarm relay is very versatile and can be set to operate in one
of six di󰀨erent ways. If you choose yes to “use the alarm relay” you are
confronted with the rst of seven screens asking you how you would like
the alarm relay’s contacts to behave. You can move through the choices
using the up and down buttons. Details of the six choices follow.
1) Closed if any Fault Develops (Remains open if ow stops)
If you want the alarm relay to close its contacts only when a genuine fault
develops simply press (P) to accept this choice. Alarm on a fault means
the alarm relay will only close its contacts if the pump runs dry, if ow is
interrupted while cyclically running or while a batch is running of if the anti
cycling starts per hour rate is exceeded. To respond to dry running the F29
has to have an external pressure switch connected to its remote input and
you must have selected “use remote input, yes” and then select “use
remote for starting only” for the F29 to be able to di󰀨erentiate between
normal ow stopping and a genuine dry run.
If you have set run dry auto restart to on and have chosen repeated restarts
from the run dry menu then in the event of the pump running dry the alarm
relay will not close. This is because choosing repeated restarts means you
accept the pump running dry as a normal event and not a true fault. If you
require an alarm using this run dry conguration then using “alarm on loss
of ow would be the appropriate choice. If you choose single restart from
the run dry menu and the pump runs dry the alarm relay will not close its
contacts unless the second attempt at restarting fails and the controller
goes into permanent alarm mode.

4
2) Closed if Flow Stops (Remains open if a fault develops)
The second alarm choice means the alarm relay will close its contacts
every time ow stops, unless there is a fault. This means stopping under
normal circumstances. It means the alarm relay will not close its contacts
if a fault occurs, as it would if you had made the previous choice. Such
faults that will not cause an alarm include running dry, ow interruptions to
batch or cyclic running and the anti cycling alarm.
3) Closed if Pump is O󰀨 (Regardless of ow or faults)
This choice e󰀨ectively provides a set of voltage free contacts that act in
reverse to the main pump relay’s contacts. That is, the alarm relay’s
contacts will be closed when the pump relay’s contacts are open and they
will be open when the pump relay’s contacts are closed. This conguration
can be used for all manner of special applications where a set of independent
electrical contacts are required. It is even possible to control a second
pump via the relay’s contacts. This can be done either directly or via an
interposing contactor. The standby pump would only run when the main
pump was o󰀨.
4) Closed if Pump is On (Regardless of ow or faults)
If this conguration is chosen the alarm relays contacts will mimic the main
pump relay’s contacts. They will be closed when the pump relay’s contacts
are closed and open when the main pump relay’s contacts are open. Like
the previous choice, this conguration lends itself to all sorts of special
control applications.
5) Closed During Pre-Start Delay (Remains open at all other times)
If you decide to use this option the contacts of the alarm relay will only be
closed while the pre-start timer is running. See details of what the pre-start
timer is and what it does on page 6. Basically the alarm relay contacts can
be used to control some external device for a period of time prior to the
pump turning on. A typical application would be to have an aeration system
or mixer run for a set period of time and then shut down and then have the
pump turn on automatically. Such applications are often encountered in
inuent and e󰀪uent mixing and processing systems.

5
6) Closed on Faults Not in Cyc Run (No alarm in Cyclic Running)
This option is similar to option 1, “Closed if Any Fault Develops” the only
di󰀨erence being that the alarm relay will not close its contacts if an
interruption to ow occurs during cyclic running. All other faults will cause
the alarm relay to close its contacts. This alarm option allows the pump to
be used to cyclically pump a bore for a set period and then wait for the
standing water level to recover before repeating the process. In this
situation If the pump runs dry the cyclic running will simply revert to its set
stopped time without locking out and instigating an alarm as it would if
option 1 was used.
7) Closed on Flow, Opens on No Flow
If you select this option the alarm relay will behave like a separate basic
ow switch that will respond to ow independent of what the main pump
control relay, relay 1 may be doing. The contacts of the alarm relay (relay
2) will remain closed while ow is present and will remain open if no ow is
detected. There are no timer functions associated with this action. The
relay contacts will mimic the action of a simple on/o󰀨 ow switch and
respond directly to ow.
Start-up and Run-on Timers
After the alarm relay selection comes the start-up timer screen. This is set
to 5 seconds as the factory default. You can increase or decrease this by
pressing the up or down buttons and then pressing the (P) button to step
to the next function, the run-on timer. The run-on timer is also set to 5
seconds by default and again you can increase or decrease this by pressing
the up or down buttons. The start-up timer has a range of 0 to 240 seconds
and the run-on timer can be set from 0 to 900 seconds. Both the start-up
and run-on timers are self terminating. This means they cancel out their
runs and revert to normal pump running as soon as ow is detected rather
than running for the full time that you have entered. In addition, the run-on
timer automatically resets its clock each time ow is detected. This feature
means the F29 will ignore entrained gas in the pipe system. The ow has
to remain continuously o󰀨 for whatever time you set on the run-on timer for
the pump to stop. The pump may be running dry for the period you set on
the run-on timer so take care not to set a run-on time that is longer than
absolutely necessary.

Once you have set the start-up and run-on timers and pressed (P) to
conrm the settings you are presented with a screen that asks if you want
to use the advanced functions of the F29. If your application only requires
dry run protection for a pump and a start override to get the pump going in
spite of an initial lack of ow then you will not require the advanced functions.
In this situation just accept the default “NO” and press (P). You will then be
asked to conrm your choice and press the (R) reset button to run the
pump.
Advanced Functions
The F29 programmable ow switch includes a set of advanced functions
that extend the capability of the ow switch well beyond basic loss of ow
protection. The advanced functions are directly accessible by moving
beyond the more basic start-up and run-on timers previously described.
There follows here a detailed description of each of the advanced functions.
Advanced functions can be used singularly or in combination with other
advanced functions as well as with the start-up and run-on timers and with
or without an external remote switch. Some advanced functions conict
with others and the F29 ow switch will automatically step over conicting
functions in its menu based on your progressive selections.
Reversing the Contacts of Relay 1
On moving into the advanced functions section of the F29’s menu you are
rst presented with the option to reverse the contacts of relay 1. Relay 1 is
normally used to control a pump and its contacts are open when o󰀨 and
closed when the pump is running. In some applications it is desirable to
have the contacts of relay 1 closed when the pump is o󰀨 and open when
the pump is running. An example of the use of reverse contacts would be
on an engine pump set where the contacts of relay 1 are open while the
engine is running and close to ground out the engines ignition circuit when
the pump stops. To reverse the contacts of relay 1 simply select “YES”
using the down arrow button. Pressing (P) locks your selection in and
moves you to the next option.
6

Pre-Start Delay Timer
The F29 includes a pre-start delay time. The pre-start delay timer delays
the starting of the pump for a selectable period. It can be set from zero to
64,800 seconds (18 hours) in 1 second increments. If you choose to use
this timer the actual starting of the pump will be delayed by whatever time
you set this timer to. Each time the F29 is switched on it boots up but
prevents the actual starting of the pump for the set period. As soon as the
set time has elapsed the pump will start and run normally. The pre-start
timer can be used to allow peripheral equipment time to boot up or to run.
For example, some VS drives require a few seconds to stabilise and the
F29 pre-start delay timer can hold o󰀨 the starting of the pump until the
system has stabilised. The pre-start timer can also be used to stage or
stagger the starting of multiple pumps. If you want to use the delayed
starting function press the up or down buttons to display “YES” and then
press the (P) button. You will then be able to enter your required delay
period using the up and down buttons. When you have entered your
required time press (P) to move on to the next function.
Batch Control
The batch control function built into the F29 ow switch lets the user
program into the switch a set running time for the pump. The range of
adjustment is 1 minute to 99 hours 59 minutes in increments of 1 minute.
If you select “YES” to batch control you are asked if you require single or
repeated batches. Single batch control is just that, a single batch that runs
with no additional options. Selecting repeated batch enables delayed
restarting, a function that follows batch control in the main menu. If the
batch run is interrupted by loss of ow it can be set to restart at the beginning
of its run after a delay period of 1 minute to 99 hours 59 minutes. If you
select single batch from the menu, delayed restarting does not appear in
the menu as an option.
The running of the set batch time can be initiated by powering up the F29
or by pressing the (R) reset button. The batch run can also be initiated by
the closing of the contacts of a remote switch connected to the F29’s
remote input. To use the batch controller in this way, rst set the remote
7