KELCO F29 PROGRAMMABLE
FLOW SWITCH
PROGRAMMING INSTRUCTIONS
Version 010916
KELCO Engineering Pty Ltd
Sydney Australia
www.kelco.com.au
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
Page
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.
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 specically 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.
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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 conrming 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
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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 dierent 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 dierentiate 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 conguration 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.
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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 eectively 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 conguration
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 conguration 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 conguration 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
inuent and euent mixing and processing systems.
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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
dierence 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.
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Once you have set the start-up and run-on timers and pressed (P) to
conrm 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 conrm 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 conict
with others and the F29 ow switch will automatically step over conicting
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
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input to on and to start only mode. Each time the remote switch closes its
contacts a batch run will be initiated. If the remote switch contacts remain
closed the F29 simply runs for the set period and then shuts down. To
initiate another run the remote switch contacts must rst open and then re-
close.
If ow is lost during a batch run, due to the pump running dry or a valve
closing, the F29 will shut down the pump. If ow subsequently resumes
the batch controller will re-initiate its run from the beginning. It will not
resume running from the point in its previous run that it shut down at. This
function can be used in tank lling applications to send a set volume of
water to a tank but to terminate the batch run when the tank lls.
When using the batch control function with the remote input in start only
mode the F29 also uses the remote input as a means of detecting dry run.
In this scenario the remote input would ordinarily be connected to an
external pressure switch. If ow is lost and the contacts of the remote
switch are closed the F29 identies this as dry run , no pressure and no
ow, shuts down the pump and displays the message “pump ran dry”. In
this conguration the contacts of the alarm relay close. The contacts can
be used to actuate an external alarm or light. The alarm relay contacts
also close at the completion of the batch run and again can be used to
indicate the completion of the run via an external alarm or light.
Batching With Additional Functions
If you choose to use the F29 batch controller, you can also use some
additional functions at the same time. Once you make the choice to use
the batch controller the F29 automatically makes available to you functions
that will work while the batch controller is in operation. Functions that will
not work with the batch controller are automatically stepped over by the
menu program. Functions that will not work include cyclic running, burst
pipe detection and leak detection.
If you choose to use a function such as delayed restarting please be aware
that when the delayed restart is invoked the batch controller resets its run
time to your original entered value. At the end of the delay time the pump
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will start and run your set batch from the beginning. This process will
repeat each time the pump shuts down for any reason, the batch counter
will reset and run your batch from the start.
If you choose to use the batch controller the F29’s cyclic running function
will be disabled. If you choose not to use batch control then cyclic running
will appear in the menu. Cyclic running can be used for batch control. To
do this set the cyclic running time to some value and set the cyclic stopping
time to zero. In eect, zero stopping time means innite stopping time as
there is no dened set stop time. Set up this way the F29 will run for
whatever time you have entered into the cyclic running run time and will
then stop. This batching process can be repeated by pressing the reset
button or by closing the contacts of an external switch, if you have chosen
to use the remote input.
Delayed Restarting
If you set this option to on, each time the pump stops, due to ow stopping
or pressure rising above your external pressure switch’s set point, the F29
will prevent the pump from restarting for the set period of time. The delay
time can be set from zero to 99 hours 59 minutes in increments of 1 minute.
Delayed restarting is a form of anti-cycling and cyclic running, wherein the
pump is limited in its ability to cycle on and o by preventing it from restarting
for a set time period. Its uses include preventing rapid cycling if the system’s
air cell becomes water logged or if a fault develops in a system’s external
pressure switch. As an example of its use, consider a pressure system
lling a remote tank. If the tank has a oat valve that shuts when the tank
is full, then the system will pressurise and shut down each time the tank
lls and the valve closes. If the oat valve leaks or the level drops and the
valve opens the system will depressurise and the pump would ordinarily
start. By utilising the F29’s delayed starting feature, the restarting of the
pump can be delayed for a period of time. Perhaps until the water level in
the tank has dropped by a substantial amount.
If you choose to use the delayed restarting function and press (P), you will
be asked to enter the delay hours and minutes. You will then be asked if
you want automatic starting at the end of the delay period. If you choose
yes to this question the ow switch will automatically start your pump at the
end of the delay period. If you choose no, the ow switch will only start the
9
pump after the delay if an external switch connected to the F29’s remote
input closes its contacts. In the example outlined above, consider a tank
that has intermittent or irregular draw o. You may choose to set the
delayed restart to perhaps 12 hours. At the end of the 12 hour period the
pump will automatically start and if the tank level is low, the pump will run
continuously until the tank lls and the oat valve in the tank closes. If
however, there has been no draw-o from the tank during the 12 hour
period, the automatic restart at the end of the delay will start the pump and
run it for whatever period you have set on the start timer (perhaps a few
seconds). The F29 will sense no ow because the oat valve will still be
closed. The F29 will then shut down the pump and again wait for 12 hours
before again attempting to start the pump. Using this technique prevents
the pump from hunting on and o when the tank is full because of slight
leakage from the oat valve or pipework. It allows you to set the pump to
only operate after a chosen delay, and if there has been no usage of water,
to test the system for demand by momentarily starting, and only run the
pump if there is a genuine call for water.
The delayed starting function is distinctly dierent in the way it operates to
the cyclic running function that is also included in the F29. Delayed
restarting has no xed run time. Once started, the pump will run continuously
provided ow is present until it is stopped by a valve closing or until it runs
dry. Cyclic running allows you to set how long the pump runs for as well as
how long it stops for. If you choose to use the delayed restarting option the
cyclic running function that follows it will not be available to you, as its
operation oers an alternative to cyclic running that excludes the
combination of the two functions.
Cyclic Running
The F29 can be programmed to run and stop a pump for set periods of
time. Both the running and stopping times can be set to any value you
choose from 1 minute to 99 hours 59 minutes in increments of 1 minute.
The cyclic running option is highly exible. The run and stop timers are
totally independent of each other. If a set running and stopping time are
programmed in, the ow switch will run the pump for whatever time it is set
to and then stop for the time set on its stop timer.
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If a run time is set to some value and the stop time is left set at zero, the
ow switch will behave as a one-shot batch controller. On pressing the
reset button or switching the pump on, the pump will run for the set period
and then shut down. It will not then restart until you again press the reset
button or reset the power to the unit. In cyclic running mode the ow switch
monitors the elapsed time and displays the remaining time on its LCD
screen in hours and minutes.
Cyclic running allows low yield bores to be pumped to their maximum
capacity. A bore pump running under cyclic control can be set to pump the
bore down to a low level, stop and wait for the standing water level to
recover and then repeat the process endlessly. For transfer pumping
applications cyclic running can be used to automatically top up remote
tanks without the need for oat valves or level control at the tank. It can
also be used for one-shot tank lling. Press the reset button and pump a
set number of hours of water to a tank, and then stop until the reset is again
pressed.
Auto Restart
If the F29 ow switch is used in conjunction with an external pressure
switch that is connected to its remote input it will be able to detect if the
pump has run dry as a combination of no ow and low or no line pressure.
If the pump does run dry the auto restart function can be set to automatically
restart the pump after a settable time. Note that the auto restart function
only appears in the F29’s menu if you have rst selected to use the remote
input and have selected “start only” from its options.
If auto restart is chosen, the F29’s menu presents you with a choice,
single restart or repeated restarts. Single restart will attempt to restart the
pump after a set time and if the attempt fails the F29 then shuts down the
pump and goes into permanent alarm mode. It displays a “pump ran dry”
message, ashes all its lights and closes the contacts of its alarm relay (if
you have chosen to use the alarm relay). If however, it nds ow when it
restarts it resumes normal operation. If you choose repeated restart from
the menu the F29 will repeat the shut down and wait sequence and it will
not go into permanent alarm mode. Once you choose repeated restart or
single restart the screens that follow ask you to enter a waiting period in
hours and minutes. The range of adjustment is 1 minute to 99 hours 59
11
minutes (zero to just over 4 days) in one minute increments. If the pump
runs dry the F29 will shut it down and wait for the period you have set
before attempting to restart.
The ability to restart the pump automatically if it runs dry can be a very
useful function. Consider a jet pump or submersible pump installed in a
low yield bore. The bore can be pumped until dry and the pump under the
control of the F29 can be set to shut down as soon as loss of ow is
detected and then wait until the standing water level in the bore recovers
before attempting to restart and again pump the bore down.
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).
Maximum Starts Per Hour
The anti-cycling option built into the F29 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
specic 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 for a settable number of consecutive times in any one hour
period the pump will be automatically shut down and the ow switch will
display a message indicating the starts per hour rate was exceeded.
Number of Starts in Sequence
Once you have selected a suitable maximum number of starts per hour
and pressed (P) the screen that follows asks you how many pump starts
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you would like the F29 to tolerate in sequence. The default setting is 5.
You can change this using the up and down buttons. The range of
adjustment is 2 to 50 sequential starts.
As a simple example of the way the anti-cycling system works, if the starts
per hour rate is set to 360 (one start every 10 seconds maximum) and the
pump started 4 times in a row at less than 10 seconds between each start
and then did not start again for 12 seconds, the anti-cycling shutdown will
not be invoked. If however, the pump were to start 5 times in a row with
less than 10 seconds between the starts the anti-cycling system would be
invoked and the pump would be shut down.
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 o rapidly.
Such rapid cycling will cause the pump to overheat very quickly. The F29’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.
Burst Pipe Detector
The F29 includes a unique system for detecting burst pipes. It is most
commonly used in systems that are set up as a pressure system and are
controlled by an external pressure switch connected to the remote input
terminal of the ow switch.
If a pressure system bursts its discharge pipe the system pressure will fall
and the pump will start at its low pressure setting. The pump will then run
continuously until the water source is depleted. If the discharge pipe splits
and the pump has sucient capacity the result may be continuous cycling
of the pump as it attempts to satisfy the leak. The F29 addresses these
two scenarios with two separate functions, anti-cycling and burst pipe
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detection. When both functions are activated the complete spectrum of
possibilities is covered. Anti-cycling will detect cyclic starting and stopping
and can be set to shut the pump down after a predetermined number of
cycles. This function detects split and leaking pipes.
The burst pipe detector addresses the issue of a completely burst pipe
where the pump would ordinarily discharge at its full capacity until the
source of water was depleted. It does this by using a timer that times out
for a settable period each time the pump runs. The timer resets back to its
original setting each time the pump stops. The range of adjustment is zero
to 99 hours 59 minutes in increments of 1 minute.
In a typical application the burst pipe detector would be set to some time
that was marginally longer than the longest time the pump would ordinarily
run. For example, in a domestic pressure system day to day usage may
require the pump to run for no longer than 15 minutes (for showers etc.).
Perhaps once every few days the system is used for garden watering and
required to run for 30 minutes. In this scenario the burst pipe detector
would be set to 35 or 40 minutes.
Each time the pump switches on the burst pipe detector begins to count
down. In normal circumstances the pump will shut o in less than 30
minutes. This resets the burst pipe detector’s timer back to 40 minutes. If
however, the pump continues to run, due perhaps to a burst pipe, it will
eventually reach the set point of 40 minutes. The pump will then be instantly
shut down preserving whatever source water remains. The F29 will then
display “burst pipe detected” on its LCD screen.
The setting of the burst pipe detector is a matter of balance between
nuisance tripping and maximum preservation of the water source. If the
burst pipe detection timer is set too close to the actual maximum usage
time, the system may trip out occasionally due to slightly excessive water
usage. If however, the timer is set too long the result will be wasted water
in the event of a genuine burst pipe.
The burst pipe detection system can be used to protect water reserves in
tank lling and transfer pump applications. As an example, consider a tank
lling application. The capacity of the pump and the tank are known so the
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maximum run time of such a system will be the time required to ll the tank
when it is completely empty. Draw o from the tank may add to this time
but fundamentally the time will be known within reasonable bounds. If the
level switch in the tank fails or the oat valve fails and the tank continuously
overows, eventually the pump under the control of the F29’s burst pipe
detector will reach the burst pipe detector’s set point and the pump will be
shut down preserving what remains of the water source.
Leak Detector
The F29 includes a unique leak detection system that can be used to
analyse suspected leakage in a pressurised pumping system. The leak
detector can be switched on or o in the main menu. It should be left
switched o when not required as its display screen excludes the display
of normal system messages when it is in use.
The leak detection system will only operate in systems where the F29 is
connected to an external pressure switch as it relies on the opening and
closing of the pressure switch to count pump starts and to evaluate pump
running time. It will not operate in systems where the F29 is connected to
tank level switches or other external devices. The leak detector will not
appear in the F29’s main menu unless all other functions are turned o with
the exception of the remote input and the start and run-on timers.
When selected it operates in the following way. Open all valves feeding into
the pipe system to be checked. Close all valves at the extreme ends of the
pipe system so the system can be pressurised. Press the reset button on
the controller, this will zero the leak detector screen and run the pump until
the system is fully pressurised. Leave the system unattended for a period
of time perhaps an hour or even a day or two. On returning to the system,
the ow switch’s LCD screen will be displaying the number of times the
pump started and the total run time in hours minutes and seconds since
the time the leak detector was zeroed.
If the leak detector screen displays no starts and no run time, then no leak
has occurred from the system in the interim period. If the screen displays a
number of starts and a total run time, a leak has occurred and the magnitude
of the leak can be assessed by considering the total run time displayed and
the capacity of the specic pump. The leak detector can be used in any
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pressurised pumping system, eg: from a small domestic pressure or
transfer system to complex irrigation and stock watering systems comprised
of many kilometres of pipe.
Program Lock
The F29 ow switch has a hidden security lock. When activated, the lock
disables the programming button P and prevents access to the F29’s
menu. To lock or unlock the ow switch, press the up and down buttons
together while the pump is in normal operation (not while it is being
programmed). Pressing the up and down buttons together while in normal
running mode shuts down the pump and opens the ow switch’s lock
screen. Once the lock screen is displayed the ow switch can be locked or
unlocked by pressing the up or down buttons. Pressing (P) then exits the
lock screen and the ow switch resumes normal operation. When locked,
pressing the (P) button has no eect on the ow switch and does not take
you into the menu in the usual way. Access to the menu can then only be
obtained by rst unlocking the program.
Running Time Display
The F29 keeps track of how long a pump under its control runs for. The
total for any given run is displayed on the LCD screen each time the pump
stops. This information is displayed along with any other relevant
information about the state of the pump or the reason for the shutdown by
alternating the information at 5 second intervals on the LCD screen while
the pump is o. The time display is in minutes and it accumulates while
ever the pump runs. The time resets to zero each time the pump starts or
the reset button is pressed or each time power is reset (switched o and
back on). The time that a pump runs for can be useful information to have.
For example if a pump under the control of the F29 runs dry then it is useful
to know how long it ran for before it ran dry. Consider an irrigation system
where the F29 has detected a problem during a xed irrigation cycle and
shut the pump down. It is very useful to know how long the pump ran for
before the shutdown occurred.
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The Hour Meter
The F29 has a built in hour meter that keeps track of the total time a pump
under its control runs for. The hour meter can be used for scheduling
routine maintenance or for monitoring total water intermittently or
continuously pumped over long periods. The hour meter displays the total
hours run for 2 seconds each time the pump stops. It is viewable by
watching the LCD screen carefully during this 2 second period as the F29
shuts the pump down. The hour meter can also be viewed and reset to
zero from within the programming menu. Press the (P) button to access
the main menu and press it again to display the controller’s model number
screen. With the display showing “F29 CONTROLLER”, press the UP
arrow button and the hour meter will display. The time displayed on the
hour meter represents the actual hours the pump has run for in total. To
reset the hour meter to zero, press the down arrow button. To exit out of
the hour meter screen press (P). The hour meter accumulates running
time and does not lose its memory of the total pumping hours even if the
power is switched o for extended periods. The meter can accumulate up
to 7.4 years of total running time ( in hours) before it automatically resets
to zero.
LCD Screen Back Light
The LCD screen on the F29 ow switch has a built-in backlight. The
backlight switches on automatically whenever you are programming the
ow switch and when the F29 is displaying certain fault conditions. In
normal operation the backlight remains o.
The LCD screen backlight can be switched on manually at any time by
pressing and holding down the down arrow button. The screen will remain
illuminated while you are depressing the down button. The screen will
switch o as soon as you release the button. The LCD backlight can’t be
permanently switched on, it only operates while the down button is pressed.
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WARNING
If the F29 Flow switch is used in a manner not specied
by the manufacturer the pump protection provided by
the ow switch may be impaired or negated. In addition,
all warranties stated or implied will be rendered invalid.
Designed and Manufactured in Australia by
KELCO Engineering Pty Ltd
A.B.N. 20 002 834 844
Head Oce and Factory: 9/9 Powells Road Brookvale 2100 Australia
Postal Address: PO Box 7485 Warringah Mall NSW 2100
Phone: +61 2 99056425 Fax: +61 2 99056420 Email: sales@kelco.com.au
Web www.kelco.com.au
PLEASE NOTE: Kelco Engineering Pty Ltd reserves the right to change the specication of this
product without notice. Kelco Engineering Pty Ltd accepts no liability for personal injury or economic
loss as a consequence of the use of this product. All rights reserved copyright Kelco Engineering
Pty Ltd © 2016
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.
To change the functions of this controller please rst read the programming book supplied with this unit.
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.
VERY IMPORTANT
IMPORTANT
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