KELCO IPG20 Mk2 Installation & Programming Manual Download

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KELCO IPG20 Mk2

INTELLIGENT PUMP GUARD

INSTALLATION & PROGRAMMING

MANUAL

KELCO

Engineering Pty Ltd

Sydney Australia
www.kelco.com.au

Version 150119

Summary of Contents for IPG20 Mk2

Page 1: ...KELCO IPG20 Mk2 INTELLIGENT PUMP GUARD INSTALLATION PROGRAMMING MANUAL KELCO Engineering Pty Ltd Sydney Australia www kelco com au Version 150119...

Page 2: ...res extensive knowledge of pump engineering and electrical engineering Installation must always be carried out by a qualified pump engineer and all electrical work associated with this controller must...

Page 3: ...low pressure due to a leak With the IPG20 each time the pumping system is started and after the operator has verified the system is running with no problems the learning phase of the controller can be...

Page 4: ...unning 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...

Page 5: ...2 Do not expose the IPG20 to freezing If the pipework in which the IPG20 is installed freezes the pressure sensor in the controller may fail If the IPG20 is to be used in areas where low temperatures...

Page 6: ...th 5 diameters of straight pipe either side of the paddle The controller can be installed in a suitable pipe socket tapping saddle or pipe tee The controller should be installed in the discharge pipew...

Page 7: ...ur hand from the top of the housing Pressing down with your hand on the housing preloads the O ring seal between the housing and the paddle assembly It enables the M4 Allan screw to easily screw fully...

Page 8: ...system that can exceed the pressure rating of any component on that system Alternately always confirm that the pressure safety limits of individual items are compatible and not compromised without th...

Page 9: ...ion thread on the controller and screw the controller into the pipework using the spanner flats on the process connection Do not screw the controller into the pipework by twisting the electrical housi...

Page 10: ...a substantial force from the moving water to move the paddle If you wind the sensitivity adjustment screw anti clockwise outward the force against the paddle that resists flow will be reduced The padd...

Page 11: ...Hz supply when operated from the mains It can also be operated from an 18 to 24V AC or DC supply by utilising the low voltage active terminal LV and neutral terminal N see the included wiring diagrams...

Page 12: ...er any circumstances When the HD terminal is linked to the normally open terminal of Relay 1 the HD drive in effect parallels a 42 Amp solid state switch across the relay s normally open contacts This...

Page 13: ...of steel crimp rings The crimp rings are to provide strain relief for the controller s cables To use the crimps place one on the cable approximately 3 to 4mm below the end of the cable s outer sheath...

Page 14: ...motor up to 2 4kW Without the HD terminal link in place relays 1 2 are limited to directly controlling a motor to 0 75kW Both relays can control motors of any size via interposing contactors VOLTAGE...

Page 15: ...t 2 and used to reboot the IPG20 In effect the remote switch acts like the reset button on the IPG20 itself It causes whatever process is running to stop and for the controller to reboot If the remote...

Page 16: ...t use alarm relay and then select relay closed whenever pump is stopped No 2 Relay that tells the controller you are going to use valve sequencing When you then get deeper into the menu and are asked...

Page 17: ...ol of a Single Phase Pump with an Alarm and two remote inputs Remote switches with NO or NC voltage free contacts This link wire must be used whenever the controller is directly controlling a single p...

Page 18: ...ase pump motor as shown Do NOT use the HD link in 3 phase or single phase control circuit applications Pump Motor 2 Single Phase 110 240VAC Motor 0 75kW Max when controlled directly through relay 2 as...

Page 19: ...actor WARNING Contactor coil rating must not exceed 240VAC BASIC 3 PHASE PUMP CONTROL DUAL 3 PHASE PUMP CONTROL DUAL 3 PHASE PUMP CONTROL 3 Phase Pump Motor 1 N L3 L2 L1 3 Phase Pump Motor 2 WARNING C...

Page 20: ...Motor Alarm 16A 240V Maximum resistive load N L3 L2 L1 Contactor WARNING Contactor coil rating must not exceed 240VAC IPG20 24V WITH REMOTE AND LOW VOLTAGE SOLENOID VALVE Remote switch 3 Phase Pump M...

Page 21: ...UIT REMOTE 24V SOLENOID VALVE IPG20 240V WITH REMOTE AND LOW VOLTAGE SOLENOID VALVE Remote switch 3 Phase Pump Motor N L3 L2 L1 WARNING Contactor coil rating must not exceed 240VAC Contactor 24VAC Sol...

Page 22: ...ve terminal This link wire must be used whenever the controller is directly controlling a single phase pump motor as shown Do NOT use the HD link in 3 phase or single phase control circuit application...

Page 23: ...by a positive and a negative terminal Supply voltage across the positive and negative terminals must never exceed 24VDC or the flow switch will be damaged The supply terminals are reverse polarity pr...

Page 24: ...ing button P can be locked LOCKING THE IPG20 To activate the lock press and hold down the and buttons and then press and release the R button Continue to hold the and buttons down until the screen dis...

Page 25: ...degree of protection against over pressure due to a blockage or low pressure due to a leak With the IPG20 each time the pumping system is started and after the operator has verified the system is run...

Page 26: ...selected The switch will then adjust itself to compensate for a changing contour This allows for very small over and under pressure margins which gives a very high degree of protection against leaks o...

Page 27: ...timer Run on timer Loss of flow protection Cyclic running For use with pod systems Auto restart on a fault Not available with auto terrain compensation Valve sequencing Uses the second relay to trigge...

Page 28: ...or broken main line Low pressure margin 20kPa Small leak More than 20kPa pressure drop will trigger the dip timer Absolute high limit Set to below max head of pump and below max pipe pressure and at...

Page 29: ...ll leak More than 20kPa pressure drop will trigger the dip timer Absolute high limit Set to below max head of pump and below max pipe pressure and at least 50kPa above expected maximum operating press...

Page 30: ...inal It is critical that the remote switch has voltage free contacts Under no circumstances apply an external voltage directly to the R terminal of the IPG20 pump guard Aremote momentary on switch can...

Page 31: ...ng either up or down a slope then the expected change in pressure is directly related to the change in height If the irrigator travels 100 meters per hour and the steepest slope it is expected to move...

Page 32: ...r can hold off the starting of the pump until the whole system has stabilised The pre start timer can also be used to stage or stagger the starting of multiple devices It is often desirable to avoid t...

Page 33: ...ts will be open and when the pump relay is off the alarm relay s contacts will be closed This configuration has all manner of applications in general control and in operating peripheral equipment This...

Page 34: ...ers priming valves and any other device that it is useful to run with or prior to the pump starting Once selected it closes the alarm relay contacts either as soon as the prestart delay starts or if t...

Page 35: ...ue than the low pressure trip point the IPG20 will not accept the setting and advise you to check your settings If you choose to leave the high pressure trip point set at zero meaning you don t want a...

Page 36: ...em For a fully primed system the start up timer may only require one or two seconds to establish flow In a submersible bore pump installation with a self draining riser it may take several minutes to...

Page 37: ...G20 reverts to running the pressure dip timer The purpose of the pressure dip timer is to let the pump system tolerate minor dips in pressure without shutting down the pump Minor dips in pressure can...

Page 38: ...ple if air trapped in the pipework passes the pump guard s paddle the paddle will momentarily swing into the no flow position This would normally cause the pump guard to shut down the pump The run on...

Page 39: ...es AUTO RESTART ON A FAULT The system can be restarted automatically after a fault condition has shut thepumpoff Theswitchwillonlyrestartthepumponceafterapredetermined time and if the fault reoccurs i...

Page 40: ...he alarm relay close its contacts when the pump stops in normal cyclic running AUTO RESTART ON A FAULT The system can be restarted automatically after a fault condition has shut thepumpoff Theswitchwi...

Page 41: ...one fault condition while the alarm relay responds to a separate condition For example you could set the alarm relay to only close its contacts if the pump ran dry and have the pump only automaticall...

Page 42: ...oduct Warranty applies to all Kelco Products regardless of where you purchased the Kelco Products When you place an order you are deemed to agree to the Warranty unless otherwise agreed in writing wit...

Page 43: ...e 3 Precautions You are deemed to accept the following terms and conditions when you purchase Kelco Products 1 You will use Kelco Products in compliance with Usage Conditions including rating and perf...

Page 44: ...de any warranty for such Kelco Products except for specific applications where Kelco has specified that it intends to provide a warranty or by separate written agreement between the customer and Kelco...

Page 45: ...or evaluation Kelco will provide delivery details and a return goods authorisation number to you The Kelco Products will be at the owner s risk whilst in transit to and from Kelco unless transported...

Page 46: ...n Kelco may not provide customers with Kelco Products and or technical documents should they fail to comply with such laws and regulations PLEASE NOTE Kelco Engineering Pty Ltd reserves the right to c...

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