KELCO IPG20 Mk2 Montageanleitung

KELCO IPG20 Mk2

INTELLIGENT PUMP GUARD

INSTALLATION & PROGRAMMING

MANUAL

KELCO Engineering Pty Ltd

Sydney Australia

www.kelco.com.au

Version 150119

VERY IMPORTANT SAFETY NOTICE

PLEASE READ THIS BEFORE INSTALLING THIS CONTROLLER

The IPG20 Mk2 is an industrial control device. It is specically designed

for use in dairy and agricultural applications. It must never be used for any

application other than for the aforesaid purposes. The installation,

commissioning of this pump controller requires extensive knowledge of

pump engineering and electrical engineering. Installation must always be

carried out by a qualied 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 this pump controller by a person responsible for their

safety.

IMPORTANT: READ THIS FIRST

DO NOT EXPOSE THE IPG20 Mk2 TO VIBRATION. INSTALL ONLY IN

PIPEWORK THAT DOES NOT VIBRATE. Vibration will damage the

electronics within the IPG20 and will void your product warranty.

OVERVIEW

The IPG20 Mk2 intelligent pump guard is a pressure and ow based device

that “learns” the operating pressure each time the system is started. This

allows for nely targeted parameters where any signicant variation in the

operating pressure or loss of ow will trigger an alarm and shut the system

down.

Because the operating pressure will change each time the irrigator or

pods are moved to a di󰀨erent hydrant or hydrant group, or even a di󰀨erent

height on the same hydrant, it is normally impossible to give a high 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 veried the system is running with no problems

the learning phase of the controller can be instigated, either 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. xed sprinklers, stationary irrigator or irrigator on

at land, then the low pressure and high pressure margin can be set very

close to the set point.

With a travelling irrigator Auto Terrain Compensation should be selected.

The switch then adjusts itself automatically to compensate for changes

in contour. This allows for a very small over and under margin, typically

10kPa or less, which gives a very high degree of protection against leaks

or blockages.

THE BUTTONS

The IPG20 is controlled and congured using 4 onboard buttons.

(R) Reset button. Stops the pump and restarts the IPG20 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 IPG20 includes 4 multicolour lights to indicate activity.

Flow: This light is GREEN when the IPG20 detects ow and RED when

no ow 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 o󰀨

when the remote is open. The light is RED when remote input No. 2 is

closed and o󰀨 when the remote is open. This light is PURPLE when both

remote inputs 1 & 2 are closed.

LCD SCREEN BACKLIGHT

The LCD backlight can be turned on or o󰀨.

To turn the light o󰀨 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 o󰀨. The light

can be left permanently on or o󰀨 as required.

TEMPERATURE

The IPG20 monitors its internal temperature when running. Pressing the

(˅) button while the controller is powered up displays the current internal

temperature of the IPG20.

PRESS (and release) THE (P) BUTTON

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. Pressing

and releasing the (P) button loads whatever the screen is displaying into

the iPG20’s memory. The memory is non-volatile and settings are retained

when power is o󰀨. 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 IPG20

1) Do not install the IPG20 in a fully exposed outdoor location. The

IPG20 is weatherproof, however, to ensure a long reliable life from it

we recommend it be protected from direct exposure to the sun and

rain. A skull cap is provided with the IPG20 and 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 meters either side

of the IPG20. Also lag the base of the IPG20 to prevent the unit and

any adjacent pipework from freezing.

3) Do not use the IPG20 in hot water applications. The IPG20 is not

designed to be used in water hotter than 60ºC.

4) Never expose the IPG20 to static or dynamic pressures greater

than 20 Bars, 290 psi.

5) Do not install the IPG20 in a section of pipe that is subject to

vibration. Vibration will cause premature failure of the electronic

components within the controller.

6) Never install the IPG20 in the suction pipe of the pump or in any

location where it may be subject to partial vacuum conditions.

LOCATION

Install this controller in a location that is sheltered from direct exposure to

the weather whenever possible. The IPG20 is weatherproof and can be

used in fully exposed locations; however, to ensure a long reliable life from

the controller we recommend it be protected from direct exposure to the

sun and rain. Intense sunlight will eventually cause discoloration of the

clear lid on the controller and will also degrade its LCD screen. It is therefore

advisable to always protect the controller from the weather using the clip-

on skull cap supplied with the controller.

The IPG20 should be installed in a straight section of pipe preferably with

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 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 horizontal or vertical pipe. If it is installed in a vertical pipe the ow must

be in an upward direction. Do not install this controller on the underside of

horizontal pipework.

WARNING: Never install the IPG20 in the suction pipe of the pump or

in any location where it may be subject to partial vacuum conditions.

INSTALLATION

The IPG20 pump guard is supplied as two separate assemblies, the

paddle assembly and the electrical housing. The paddle assembly should

be installed in the pipework rst and the electrical housing should then be

tted onto the spigot on top of the paddle assembly, taking care that the

sealing O-ring is on the stem and is in location and in good order. There is

a at 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 at 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.

With the electrical housing located on the spigot and in position, press

down with the at of your hand on the top face of the lid of the electrical

enclosure. While pressing down, screw the 4mm Allen screw fully through

the housing using the 3mm Allen Key (supplied). Tighten the screw and

then release your 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 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 will irreparably damage the controller

and void its warranty. Never apply water pressure to the controller unless

the M4 locking screw is in place and fully tightened (see sketch for details).

To t the paddle assembly into the pipework use a suitable spanner and

the spanner ats provided on the paddle assembly (directly above the

process connection thread).

The IPG20 can be installed in either vertical or horizontal pipe. When

installed in vertical pipework ow must be in an upward direction past the

controller’spaddle. TheIPG20issuppliedwitha1”BSPprocessconnection.

A matching female threaded socket or pipe tee must be provided to t the

controller into pipework.

The IPG20 is supplied with one paddle to suit pipe sizes 25mm and greater,

and two trailing wires to suit pipe sizes from 65mm - 100mm ID, subject to

velocity.

IMPORTANT SAFETY NOTE : -

A pressure relief valve should be tted to any system that can exceed the

pressure rating of any component on that system. Alternately, always

conrm that the pressure safety limits of individual items are compatible

and not compromised without the tting of appropriate safety devices, i.e.

a Pressure Relief Valve (PRV).

TRIMMING THE PADDLE

The polypropylene paddle of the IPG20 can be cut down to suit the specic

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 an appropriate

distance, subject to the expected ow, into the pipe when the controller is

installed in the pipework. If it is necessary to shorten the trailing wire it must

be tig welded to avoid fraying. If you are unsure as to what length the

paddle should be, a paddle trimming calculator is available at :

http://www.kelco.co.nz/paddle-trimming-calculator.php

If you know what the expected ow 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 and trailing wires to suit the IPG20 pump controller are available

from Kelco or from your distributor.

Apply sealing compound or Teon tape to the process connection thread

on the controller and screw the controller into the pipework using the

spanner ats on the process connection. Do not screw the controller into

the pipework by twisting the electrical housing. The controller can be

permanently damaged by twisting the electrical housing. 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 IPG20. The controller must be

square to the axis of the pipework with the direction of ow arrow pointing

in the direction of ow.

DETACHING THE ELECTRICAL HOUSING

WARNING: Always switch o󰀨 the power and de-pressurise the pipe

system before attempting to remove the electrical housing.

To allow easy access 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 o󰀨, 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 ats on the body of the

paddle housing. Simply reverse this procedure to ret the electrical housing

to the controller, taking care to ensure the O-ring on the top of the paddle

assembly is in place and is clean and in good condition.

SENSITIVITY ADJUSTMENT

Under the end of the electrical housing on the IPG20 is a red hexagonal

dust cap. If you remove this dust cap you gain access to an adjustment

screw 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 wind the sensitivity adjustment

screw anti-clockwise (outward) the force against the paddle that resists

ow will be reduced. The paddle will become increasingly more sensitive

and will respond to progressively lower ows 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 o󰀨 position when ow stops.

The range of sensitivity adjustment will also be a󰀨ected by the orientation

of the controller. In horizontal pipework with the IPG20 mounted vertically

the useable range of adjustment is approximately 8 turns. In vertical

pipework with the IPG20 installed horizontally the full 10 turn range can be

utilised.

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