KELCO IPG20 MK3 Installation & Programming Manual Download

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Engineering Pty Ltd

Sydney Australia

KELCO IPG20 MK3

www.kelco.com.au

KELCO

INSTALLATION &

PROGRAMMING MANUAL

INTELLIGENT PUMP GUARD

Summary of Contents for IPG20 MK3

Page 1: ...Engineering Pty Ltd Sydney Australia KELCO IPG20 MK3 www kelco com au KELCO INSTALLATION PROGRAMMING MANUAL INTELLIGENT PUMP GUARD ...

Page 2: ...on must always be carried out by a qualified pump engineer and all electrical work associated with this controller must be carried out by a licensed electrician This industrial control device must not be operated by persons including children with reduced physical or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning the use of...

Page 3: ...her manually or automatically after a suitable time The controller then starts to learn the operating pressure If a stable pressure is reached within the allotted time the switch will lock this pressure in as the set point and apply the predetermined under and over pressure settings If there is no expected change of pressure eg fixed sprinklers stationary irrigator or irrigator on flat land then t...

Page 4: ...embers the state it was last left in if power is turned off The light can be left permanently on or off as required When the IPG20 is powered up pressing the P button holding it down for 1 second and releasing it takes you to the top of the menu The IPG20 includes 4 multicolour lights to indicate activity Flow This light is GREEN when the IPG20 detects flow and RED when no flow is detected Pump Th...

Page 5: ...nd we recommend it be used to protect the IPG20 when direct observation of the LCD screen is not required 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 will be encountered always lag the pipework for several metres either side of the IPG20 Also l...

Page 6: ...ipe preferably with 5 diametres 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 pipework of the pumping system The IPG20 should not be installed in the suction pipe of a pump as it requires positive pressure to operate properly The IPG20 can be installed in either a h...

Page 7: ...p 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 locking screw to easily screw fully through the side of the housing Under no circumstances should the electrical housing be twisted or used to screw the paddle assembly into the pipework or to align the controller with the axis of the pipework To do so...

Page 8: ... 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 the fitting of appropriate safety devices i e a Pressure Relief Valve PRV IMPORTANT SAFETY NOTE 8 ...

Page 9: ...s to the controller s paddle the electrical housing of the IPG20 can be detached from the paddle assembly Removing the electrical housing allows access to the paddle without the need to disconnect wiring To remove the electrical assembly undo and completely remove the M4 Allen head locking screw Once the locking screw is removed lift the electrical housing straight off do not twist it when doing t...

Page 10: ...n it takes 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 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 ...

Page 11: ...s are to be used in the installation If the voltage drop associated with the starting of the pump motor is excessive the IPG20 may repeatedly reset and not operate properly The IPG20 is designed to directly control single phase pump motors to 2 4kW via its Relay 1 No interposing contactor is required for such applications The controller can also be used to control 3 phase pump motors of any size v...

Page 12: ...en 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 increases the momentary current carrying capacity of the relay s contacts to well over 60 Amps The solid state HD drive is only activated for a brief period when the motor starts and stops It effectively handles the high i...

Page 13: ...upplied with a set 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 sheathing Crimp the two ears of the ring flat using bull nosed pliers Pull the cable back through the cable gland until the crimp ring s ears are fully located into the slots in the cable ...

Page 14: ...tacts Relay 1 is normally regarded as the pump control relay and Relay 2 is normally regarded as the alarm relay When operating the IPG20 as a dual pump controller Relay 2 is used to control the second pump With the HD terminal linked to the NO terminal of Relay 1 the IPG20 can directly control a single phase motor up to 2 4kW Without the HD terminal link in place Relays 1 2 are limited to directl...

Page 15: ...ler to reboot If the remote reset switch remains closed the IPG20 displays the message RELEASE THE RESET BUTTON The IPG20 will not reboot until the remote reset button is released The supply to the remote switches must be taken from the LV terminal of the IPG20 when the controller is powered from the mains or from a 24VAC source The IPG20 must always be powered from the same source as the supply t...

Page 16: ...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 if you want to use cyclic running if you enter Yes it asks you for the running time followed by the stopping time After the stopping time a new question pops up learn the new pressure It does not appear unless you have previously sele...

Page 17: ...he HD link in 3 phase or single phase control circuit applications Remote switches with NO or NC voltage free contacts Supply 110 240VAC 50 60Hz Active Neutral Audible or Visual Alarm PLUG PLAY CONNECTIONS CONNECTIONS FOR A SINGLE PHASE PUMP Earth Link Optional voltage free external input All electrical wiring associated with this controller must be carried our by a qualified electrician WIRING DI...

Page 18: ...ever 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 applications Remote switches with NO or NC voltage free contacts Supply 110 240VAC 50 Active Neutral Pump Motor 2 Single Phase 110 240VAC Motor 3A Max when controlled directly Positive Negative Supply 18 to 24 Volts AC or DC 18 ...

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

Page 20: ...ot exceed 240VAC N L1 L2 L3 Remote switch with NO or NC voltage free contacts 3 PHASE PUMP WITH ALARM AND REMOTE SWITCH MP WITH 24V CONTROL CIRCUIT SOLENOID VALVE 3 Phase Pump Motor Solenoid Valve Contactor WARNING Contactor coil rating must not exceed 240VAC 24VAC Transformer N L1 L2 L3 Remote switch 20 ...

Page 21: ...MP WITH 240V CONTROL CIRCUIT REMOTE 24V SOLENOID VALVE 24VAC Solenoid Valve 3 Phase Pump Motor 24VAC 240 24V TRANSFORMER Contactor WARNING Contactor coil rating must not exceed 240VAC N L1 L2 L3 Remote switch 21 ...

Page 22: ...lications Supply Active Supply 120 240VAC 50 60Hz Supply Neutral Pump Motor 120 240VAC 50 60Hz Pump Motor 2 4kW Max when the HD terminal is linked Remote switch with NO or NC voltage free contacts IMPORTANT Remote input must be sourced from the supply positive terminal Alternate Positive 14 40VDC Positive Supply 11 24VDC Negative 12VDC IPG20 MK3 CONTROLLING A SINGLE PHASE PUMP 22 ...

Page 23: ...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 protected however the flow switch will simply not operate unless the supply polarity is correct If a remote switch is connected to the 12V DC IPG20 MK3 the supply to the remote switch must be taken from the positive termina...

Page 24: ...as been released release the P button The screen then displays SETTINGS CLEARED PRESS P Doing this removes any settings you may have entered and restores the controller to its default state To unlock the IPG20 repeat the above procedure press and hold down the and v buttons and then press and release the R button Continue to hold the and v buttons down until the screen displays UNLOCKED takes abou...

Page 25: ...ted time the switch will lock this pressure in as the set point and apply the predetermined under and over pressure settings If there is no expected change of pressure eg fixed sprinklers stationary irrigator travelling irrigator on flat land and little change in the liquid level relative to the IPG20 then the low pressure and high pressure margin can be set very close to the set point The pressur...

Page 26: ...lected 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 or blockages When pumping to a hydrant or group of hydrants for the first time once it has been confirmed there are no leaks or blockages and the switch has locked in a set point the operating pressure s...

Page 27: ...mer 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 trigger a valve change and relearns the pressure on the new zone Displays the system pressure in kPa Displays the high low pressure margins Displays the time the pump ran for Displays the reason for stopping ...

Page 28: ...get started All final settings are site specific and must be relevant to the installation Displayed on screen Suggested setting Function 28 Allows pressure change due to contour change Allows 1 metre per minute of height change for irrigator Pump will be started after the start after time Used to delay the pump start Configurable e g turn on a stirrer or a priming valve Protection against a major ...

Page 29: ...pe pressure and at least 50kPa above expected maximum operating pressure 20kPa Slight blockage 20kPa 10 seconds 300 seconds 20 seconds 20 seconds 10 seconds Yes 29 Not required for fixed pods Pump will be started after the start after time Used to delay the pump start Configurable e g turn on a stirrer or a priming valve Protection against a major leak or broken main line More than 20kPa pressure ...

Page 30: ...ive can be used as the source of low voltage to the remote switch and the return wire can be connected to the R terminal 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 A remote momentary on switch can be used to actuate the IPG20 controller In automatic operation after a predetermin...

Page 31: ...set point it was using at the time and the amount of pressure outside the set points that caused it to trip Where a significant change in pressure is expected due to either a change in the water level relative to the IPG20 eg pumping from a small tank with the switch in a fixed position or a travelling irrigator moving over a changing contour then auto terrain compensation can be used In this mode...

Page 32: ...t follows asks you if you want to use the IPG20 s alarm relay The IPG20 has a second relay Relay 2 that provides a set of 240VAC 16A rated normally open voltage free contacts The contacts of the alarm relay can be configured in a variety of ways both for alarm functions and to control all sorts of external equipment For example to control a mixer during the pre start delay as previously described ...

Page 33: ...ntrolled in synergy This menu choice only closes the alarm relay if a true loss of flow is detected In any other fault condition the IPG20 will shut the pump down and display an appropriate message as to what the fault was but the alarm relay will remain open unless the specific condition in this case loss of flow is detected With this choice the alarm relay will act as a set of contacts that are ...

Page 34: ...ntrol of auxillary equipment such as stirrers 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 the prestart delay is not selected it will close the contacts while the pump is running If a time is selected it will run for that period then open the alarm r...

Page 35: ...ich can be present This setting will detect a leak in the system that drops the pressure below the low pressure margin This would normally be set at the highest expected pressure anywhere in the system or perhaps at the maximum pressure rating of the pipeline The absolute high limit is the maximum pressure you want the system to reach before shutting down The range of adjustment is 0 to 2000kPa Th...

Page 36: ...le time As soon as flow is detected the start up timer terminates its run and hands control of the pump over to the paddle The start up timer is adjustable from 0 240 seconds 0 4 minutes in 1 second increments The value you enter will depend entirely on your pumping system For a fully primed system the start up timer may only require one or two seconds to establish flow In a submersible bore pump ...

Page 37: ...ers normal running Normal running is a condition where the system pressure is between the low pressure set point and the high pressure set point and flow is present In this state the IPG20 monitors both flow and pressure and ensures the system is operating properly and remains within the set parametres If the system pressure falls below your low pressure set point the IPG20 reverts to running the ...

Page 38: ...es to the absolute high value it will stop the pump instantly Once the set point is locked in the IPG20 enters normal running Normal running is a condition where the system pressure is in between the low pressure set point and the high pressure set point and flow is present In this state the IPG20 monitors both flow and pressure and ensures the system is operating properly and remains within the s...

Page 39: ...ing of a few seconds is quite adequate The self resetting action of the run on timer means it will keep a pump running in spite of repeated or continuous interruptions to flow In applications where entrained gas is present in the water the run on timer will ignore the continuous bouncing back and forward of the paddle by constantly resetting its time clock instant by instant Once running the contr...

Page 40: ...whether it ends up in permanent alarm or in auto restart waiting to restart it displays the total time it previously ran for In auto restart mode it does this by displaying alternate screens that change every 5 seconds One screen displays the reason for the shutdown and the time remaining before restart and the second screen displays the total run time The IPG20 can be programmed to run and stop a...

Page 41: ...reen displays your high and low pressure trip points in kPa It also displays the current dynamic pressure in the pipe At a glance you can see precisely what the system is doing and where the pressure is in relation to your pressure trip points In addition the IPG20 displays the flow status as a green or red flow light on its top deck and the state of the pump red for stopped and green for running ...

Page 42: ...pply voltage and motor loads The IPG20 is warranted against faulty workmanship and materials for a period of 12 months from the date of purchase Our complete warranty statement can be downloaded from If a warranty issue arises with this product contact your supplier or Kelco Engineering Pty Ltd You will be issued with a returns goods authorisation number The RGA number and proof of purchase must a...

Page 43: ...ucts are unlike conventional flow and level switches and pump controllers in that they can be applied to virtually any fluid or pumping system in any manner defined by an original equipment manufacturer a wholesaler or end user or their agents The knowledge and experience of such parties is outside the control of Kelco and their having relevant knowledge and experience is critical to the successfu...

Page 44: ... 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 by Kelco or its authorised representatives The Kelco Product presented for repair may be replaced by refurbished products of the same type rather than being repaired Refurbished parts may be used to repair the product To the extent permitted by law r...

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