KELCO F40-240-HD Installing And Using

INSTALLING AND USING
THE KELCO F40 DIGITAL PUMP CONTROLLER
WARNING
OPERATING RANGE ALL MODELS
Please read this installation sheet fully and carefully. The F40 Digital
Pump Controller is a mains voltage device. Death or serious injury
may result if this product is not correctly installed and used.
Start-up Timer
Adjustable from 1sec. to 3 minutes in 15 steps
Run-on Timer
Adjustable from 1 sec. to 5 minutes in 15 steps
Restart Timer
Adjustable from 1 min. to 48 hours in 15 steps
INTRODUCTION
Pump Start Pressure Range
0 to 5 Bars in 16 steps of 33kPa each
The F40 pump controller is a microprocessor based integrated pressure and flow
device. It is designed for controlling the operation of a pump and for protecting it
against running dry.
Maximum Starting Pressure
500kPa (72 psi)
Minimum Starting Pressure
33kPa (4.7 psi)
Recommended Pipe Sizes
25mm (1”) or larger. (There is no upper limit)
Maximum Switched Load
F40-240
250VAC 50Hz 2.4kW (Motors up to 3HP)
Maximum Switched Load
F40-240-HD
250VAC 50Hz 3.75kW (Motors up to 5HP)
Maximum Switched Load F40240-S-4
250VAC 50Hz 2.4kW (Motors up to 3HP)
Maximum Switched Load F40240-S-5
250VAC 50Hz 6Amps Non Inductive
WARNING
Maximum Switched Load
F40-24-S-5
250VAC 50Hz 6Amps Non Inductive
The F40 digital pump controller is water resistant to IP67. This rating
only applies if the clear control lid is in place and its two fixing
screws fully tightened. The F40 is not water resistant unless the clear
lid is in place and fully secured. Always replace the clear lid and
fully tighten its two screws after making changes to the settings.
The F40 may present a shock hazard and death or serious injury may
result if water enters the F40’s electrical housing. There are no user
serviceable parts in this pump controller. Under no circumstances
should the main housing be opened. Warranty on this product is
automatically void if the sealed body screws are opened.
Operating Pressure Range,
Static or Dynamic
0 to 20 Bars (0 to 300psi) See Note Below
Burst Pressure
50 Bars (750 psi)
The F40 pump controller can be used in a variety of situations to control and
safeguard a pump. Some models can directly control single-phase pump motors
up to 5HP without the need for an interposing contactor. In addition to protecting
the pump from dry run damage the F40 can be set to automatically maintain line
pressure in stock watering applications or for cyclically pumping low yield stock or
domestic bores.

IMPORTANT
This installation and usage information sheet must be read with reference to the
specific model controller being installed. The power switching capacity and the
pressure rating of the controllers vary from model to model and it is very important to
understand the limitations of a specific controller before installing it.
MODELS
F40 - 240 - S - 5
SUPPLY VOLTAGE
CABLE CORES
240 = 220 TO 240VAC
24 = 24V AC or DC
4 = 4 CORE 10Amp CABLE
5 = 5 CORE 6Amp CABLE
CABLE
NO LETTER = 10Amp PLUG & PLAY
HD = HEAVY DUTY 15Amp CABLES 2 X 2M LONG
S = SINGLE CABLE 2M LONG WITH 4 or 5 CORES
OPERATING ENVIRONMENT ALL MODELS
Supply F40-240 & F40-240-HD
220 to 250VAC 50Hz Single Phase
Supply F40-24 Low Voltage AC/DC Model
12 to 28V AC or DC at 80mA Max.
Ambient Temperature Range
1ºC to 50ºC
Liquid Temperature Range
1ºC to 60ºC See note below
Ingress Protection Rating
IP67
Maximum Operating Pressure
20 Bars 300psi
NOTE: The F40 pump controller must NOT be used in hot water applications (>60ºC). The
F40 pump controller is rated to withstand water pressure to 20 Bars (300 psi) and must
not be used in applications where the static or dynamic pressure exceeds this rating.
INSTALLATION
The F40 is suitable for use in all cold-water based applications such as potable water,
seawater, bore water, chlorinated pool water, brackish water or filtered effluent. A
suitable location should be selected for the controller in the delivery pipework of the
pump. The controller should be installed in a location that is away from both vibration
and heat, preferably out of direct exposure to the weather and above any flood level.
A 1” BSP socket, or threaded pipe tee must be provided in the pipework to fit the
controller. The controller should be located on the topside of a horizontal section
of the pipe work with a minimum of 2 diameters of straight pipe either side of the
controller. Under no circumstances mount the F40 under a pipe or close to valves,
tees, bends or any other obstructions likely to cause major turbulence in the flow.
The F40 can be mounted in vertical pipework if required, and flow can pass either in
an upward or downward direction.
In most installations the paddle of the F40 will need to be trimmed to suit the specific
pipe tee in which it is to be installed. The paddle of the controller needs a force
equivalent to 20 grams dead weight acting on it from the flow in order to operate
correctly. The force is generated by water in motion pushing against the exposed
area of the paddle. The more area of paddle exposed to the flow the more force
available to actuate the controller. Be aware that high velocity flow can generate high
forces and may damage the paddle. As a general guide the paddle of the F40 should
extend to slightly past the centre line of the pipe. The paddle would not normally
be left longer than this unless the expected flow rate was very low. If you know the
likely flow rate and the pipe size of your pump system there is an online calculator
available at www.kelco.com.au that will help you to work out an exact size to cut
the paddle. Use tin snips, side cutters or a hacksaw to cut the paddle. If needed, cut
away the sides of the paddle so it clears the pipe socket and pipe walls by at least
4mm at its closest point. Apply a suitable thread sealant tape or paste and screw
the F40 into the socket using the spanner flats provided. When properly installed
the controller should be square to the axis of the pipe, with the flow arrow on the
side of the F40’s body correctly oriented and parallel to the line of flow. In addition,
there should be a gap of at least 4mm between the top of the 1”BSP pipe socket
and the under edge of the F40’s spanner flats. Under no circumstances should the
F40 be wound into the pipe socket until its thread bottoms out in the socket as to do
so places the thread in tension and may result in the controller’s housing cracking
under pressure.
HOW TO INSTALL AN F40 DIGITAL PUMP CONTOLLER
4mm MINIMUM GAP
1”BSP REDUCING BUSH
STANDARD PIPE TEE
CUT PADDLE TO CLEAR THE
PIPE BY A MINIMUM OF 4mm
ALL ROUND
MINIMUM OF 2 DIAMETERS
OF STRAIGHT PIPE EACH
SIDE OF THE F40
ELECTRICAL
BASIC WIRING DIAGRAMS
The F40 pump controller requires a stable supply voltage in order to operate
correctly. Pay particular attention to cable sizes, and ensure cables are adequate for
the specific pump motor load. This is particularly important where long cable runs
are to be used in the installation. If the voltage drop associated with the starting of
the pump motor is excessive the F40 will automatically reset and this may cause the
pump to jog. Jogging can snap the main spindle of a pump very easily, so please
take all precautions to ensure the voltage supply to the F40 is stable and that the
current carrying capacity of the cable is adequate for the job.
Never use long or coiled extension leads (longer than 5 metres) to connect a pump
to the F40. The Standard F40-240 pump controller is supplied fitted with a 10 Amp
plug and socket. Pumps up to 2.4kW (P1) can be plugged directly into the socket
connection to the controller.
NOTE: For mains voltage applications we recommend that
the supply to the F40 be isolated by a 10Amp RCD that has a
maximum trip current of 30mA.
WARNING
NOTE
GREY WIRE & BLUE WIRE
ARE SUPPLIED AS VOLTAGE
FREE NORMALLY OPEN
CONTACTS 6Amps MAX. LOAD
BLUE WIRE
GREY WIRE
BLACK WIRE
WARNING
SINGLE PHASE 220 /240VAC SUPPLY FROM CIRCUIT BREAKER
Fixed Installations must only ever be carried out by a licensed
electrician and must conform to local wiring rules.
BROWN WIRE
BLUE WIRE
GREY WIRE
NOTE
GREY WIRE & BLUE WIRE
ARE SUPPLIED AS VOLTAGE
FREE NORMALLY OPEN
CONTACTS 6Amps MAX. LOAD
The standard F40-240 can directly control single-phase 240V~ 50Hz pump motors
BLACK WIRE
up to 2.4kW. When used in a fixed installation a disconnecting
device such as a
GREEN / YELLOW WIRE
switch or a circuit breaker must isolate the F40. The disconnecting
device must
be easily and readily accessible after installation. Where a circuit breaker is used
EARTH
it must be rated at 10 Amp. Where
an isolation switch is used the
circuit must
N
INSTALLATION
5 CORE
SWITCH FOR
ALL LOW
be protected by a 10 Amp fuse. InSINGLE
thePHASE
interests
of USING
safety
a CABLE
10 Amp
RCD
withWATTAGE
a
CONTROL CIRCUIT APPLICATIONS
maximum 30mA trip should also be installed in the supply.
N
A
EARTH
SINGLE PHASE INSTALLATION USING 5 CORE CABLE SWITCH FOR ALL LOW WATTAGE
CONTROL CIRCUIT APPLICATIONS
SUPPLY TO SWITCH
220 / 240VAC
N
SINGLE PHASE 220 /240VAC SUPPLY FROM CIRCUIT BREAKER
4 CORE CABLE SWITCHES ARE
NOT FOR THE CONTROL CIRCUIT
APPLICATION THEY ARE
STRICTLY FOR THE DIRECT
CONTROL OF PUMP MOTORS
UP TO 2.4kW MAXIMUM
TYPICAL 3 PHASE
TO CONT
BROWN WIRE
GREEN / YELLOW WIRE
SUPPLY TO SWITCH
220 / 240VAC
N
EARTH
SINGLE PHASE PUMP MOTOR
220 / 240VAC 2.4kW MAXIMUM
TYPICAL SINGLE PHASE PUMP INSTALLATION USING A 4 CORE CABLE SWITCH
IMPORTANT
4 CORE CABLE SWITCHES ARE NOT SUITABLE FOR CONTROL CIRCUIT APPLICATIONS
THEY ARE STRICTLY FOR THE DIRECT CONTROL OF PUMP MOTORS AS SHOWN ABOVE
THEY HOUSE A POWERFUL SOLID STATE DRIVE SYSTEM THAT WILL NOT WORK IN LOW
WATTAGE CONTOL CIRCUITS
5 CORE CABLE SWITCHES ARE NOT SUITABLE FOR THE DIRECT CONTROL OF PUMP MOTORS
THEY ARE FOR THE CONTROL OF CONTACTORS, RELAYS, TIMERS, PLC’S, VS DRIVES
AND OTHER LIGHT DUTY CONTROL CIRCUIT APPLICATIONS
L3
L2
L1
UNIVERSAL LOW VOLTAGE AC
3 PHASE 415VAC SUPPLY FROM CIRCUIT BREAKER
NOTE
GREY WIRE & BLUE WIRE
ARE SUPPLIED AS VOLTAGE
FREE NORMALLY OPEN
CONTACTS 6Amps MAX. LOAD
CONTRAL CIRCUIT
BREAKER OR FUSE
CONTACTOR
COIL 220 / 240V
& THERMAL OVERLOAD
BROWN WIRE
BLUE WIRE
GREY WIRE
BLACK WIRE
GREEN / YELLOW WIRE
SUPPLY TO SWITCH
220 / 240VAC
EARTH
3 PHASE PUMP MOTOR
TYPICAL 3 PHASE INSTALLATION USING 5 CORE CABLE SWITCH
TO CONTROL THE PUMP MOTOR CONTACTOR
WARNING
The F40-240-HD is supplied with heavy duty flying leads for fixed
installation use only. It must be installed by a licensed electrician
and isolated by a 15Amp fuse or a 15Amp circuit breaker. We
recommend that the supply to the F40-240-HD be isolated by a
15Amp RCD that has a maximum trip current of 30mA.
BROWN WIRE
BLUE WIRE
CONNECT BROWN WIRE TO LOW VOLTAGE
AC OR DC SUPPLY. FOR AC CONNECT IT TO
THE SUPPLY ACTIVE. FOR DC CONNECT IT
TO THE SUPPLY POSITIVE.
BLACK WIRE
GREEN / YELLOW WIRE
N
NOTE
GREY WIRE & BLUE WIRE
ARE SUPPLIED AS VOLTAGE
FREE NORMALLY OPEN
CONTACTS 6Amps MAX. LOAD
GREEN / YELLOW WIRE
N
PHASE 220 /240VAC SUPPLY FROM CIRCUIT BREAKER
A SINGLE
F40-240-HD MODEL
ONLY
SUPPLY TO SWITCH
220 / 240VAC
3 PHASE 415VAC SU
BLUE WIRE
FIXED INSTALLATION
4 CORE CABLE SWITCHES ARE
NOT FOR THE CONTROL CIRCUIT
APPLICATION THEY ARE
STRICTLY FOR THE DIRECT
CONTROL OF PUMP MOTORS
UP TO 2.4kW MAXIMUM
BROWN WIRE
L3
L2
L1
BLACK WIRE
When installing the F40 the socket outlet connection (GPO) for the
input power must be accessible, and must be positioned in a dry
and protected location out of the weather and above any flood or
water level. Where the F40 is to be used to control pump motors up
to 2.4kW 3HP the supply to the F40 must be protected by a 10 Amp
fuse or by a 10 Amp circuit breaker.
A
A
SINGLE PHASE 220 /240VAC SUPPLY FROM CIRCUIT BREAKER
EARTH
SINGLE PHASE PUMP MOTOR
220 / 240VAC 2.4kW MAXIMUM
TYPICAL SINGLE PHASE PUMP INSTALLATION USING A 4 CORE CABLE SWITCH
IMPORTANT
BROWNOUT OR BLACKOUT
4 CORE CABLE SWITCHES ARE NOT SUITABLE FOR CONTROL CIRCUIT APPLICATIONS
THEY ARE STRICTLY FOR THE DIRECT CONTROL OF PUMP MOTORS AS SHOWN ABOVE
THEY HOUSE A POWERFUL SOLID STATE DRIVE SYSTEM THAT WILL NOT WORK IN LOW
WATTAGE CONTOL CIRCUITS
5 CORE CABLE SWITCHES ARE NOT SUITABLE FOR THE DIRECT CONTROL OF PUMP MOTORS
THEY ARE FOR THE CONTROL OF CONTACTORS, RELAYS, TIMERS, PLC’S, VS DRIVES
AND OTHER LIGHT DUTY CONTROL CIRCUIT APPLICATIONS
If a blackout or brownout occurs while the F40 is operating, the controller will not
retain any memory of where in its run or stop cycle it may have been, it will simply
shut down the pump. When power resumes, the F40 will reboot, restart the pump
and run any timer settings from the beginning. A manual reboot can be done at any
time by simply pressing the reset button on the top deck of the controller.
ADJUSTING SETTINGS
There are 4 rotary switches located under the clear cover on the top deck of the
F40. These 4 dials are for adjusting the timers and pressure switch that control
the F40’s actions. To access the 4 dials undo the 2 screws that hold the clear
cover in place. Note that the clear cover must always be replaced and tightened
after making changes to the settings.

WARNING
Without the cover in place the F40 is not water resistant and
presents a potential shock hazard. Take great care not to splash
water onto the F40 when the control cover is removed and always
replace the cover immediately and fully tighten its securing screws
after any changes to the settings are made.
After you make any change to the settings on the 4 control dials you must
always press the reset button for the changes to take effect.
BROWN WIRE
BLUE WIRE
GREY WIRE
NOTE
GREY WIRE & BLUE WIRE
ARE SUPPLIED AS VOLTAGE
FREE NORMALLY OPEN
CONTACTS, 240VAC 6Amps
MAXIMUM LOAD
BLACK WIRE
GREEN / YELLOW WIRE
CONNECT BLACK WIRE TO LOW VOLTAGE
AC OR DC SUPPLY. FOR AC CONNECT IT TO
THE SUPPLY NEUTRAL. FOR DC CONNECT IT
TO THE SUPPLY NEGATIVE.
EARTH
UNIVERSAL LOW VOLTAGE AC / DC SWITCH FOR GENERAL PURPOSE CONTROL CIRCUIT APPLICATIONS
No.
DESCRIPTION
FUNCTION
1
MASTER RESET BUTTON
With power on, press this button to start the pump at any time. Always press it after making any changes to the settings on the 4 timer
dials. Any changes you have made will not take effect until you press the reset button. This button can be pressed at any time even if
the pump is running. All timers are reset to zero when the reset button is pressed.
2
PRESSURE SETTING
This dial sets the pump’s start up pressure. The dial is adjustable from zero to 5 Bars in 16 steps of 33 kPa each. If this dial is left on
zero the F40 only senses flow and not pressure. This dial is normally set to marginally higher than the system’s static pressure. When
pressure falls because a tap has been turned on a point will be reached where the pressure drops to the level set on this dial. The pump
then automatically starts and runs for the time set on the run-on dial (4). If there is a demand for flow the pump will run continuously
and satisfy the demand.
3
START TIMER
When the F40 is first turned on, or when the reset button is pressed, the start timer sets how long the pump runs for ignoring the fact
that there may be no flow or pressure present at that time. The dial can be set from zero to 3 minutes in 16 steps. During this start
time the pressure in the system must rise up to a level higher than the pressure set on the pressure dial (2). If the pressure fails to
reach the correct level by the end of the timer’s run the pump will be automatically shut down. The F40 will then rapidly flash its red
alarm light (7). Pressing the reset button (1) re-runs the start timer and adds pressure to the system until the pressure rises above the
pressure that is set on the pressure dial (2).
4
RUN-ON TIMER
If the flow is interrupted for any reason while the pump is running this timer sets how long the loss of flow is ignored before the pump
automatically shuts down. It can be set from zero to 5 minutes in 16 steps. The run-on timer also determines how long the pump runs
for if it is triggered by a pressure drop that reaches the pressure set on the pressure dial (2). Is should be set to long enough for the
pressure to rise up above the pressure dial (2) set pressure.
5
STOP TIMER
If the F40 goes into alarm mode due to being run dr, this dial sets how long the pump will remain off before the F40 attempts to restart
it. This dial is adjustable from zero to 48 hours in 16 steps. If the stop timer is set to zero the pump will not try to restart automatically
but if run dry will simply remain in alarm mode, rapidly flashing its red warning light till attended to.
6
START TIMER LED
This light shows steady blue whenever the start-up timer is running. It means the pump is running under the control of the start up timer
and the light is letting you know that when the start timer times out the pump will either continue to run, if there is a demand for flow,
or automatically shut down and wait for a pressure drop or flow demand to re-trigger it.
7
FLOW STATUS & ALARM LED
This light will show a steady green whenever the paddle of the F40 is held on by flow. It will be on at all times there is a modest flow
through the system. This light also pulses slowly red whenever the F40 is powered up and in standby mode. It indicates that everything
is OK and the F40 is simply waiting for a flow demand or a pressure drop to re-start the pump. This light also flashes rapidly red in
alarm mode if the F40 senses that the pump has run dry. If the stop timer is running this light turns steady red indicating the pump has
stopped but will re-start after whatever delay is set on the stop timer dial (5).
8
RUN-ON TIMER LED
This light shows steady red whenever the run-on timer is running. If you have set the run-on timer to say 5 seconds to ignore air bubbles
in the pipework then the pump will keep running and this light will come on steady red for 5 seconds every time air passes through the
system. This light also shows steady red whenever the system starts up on pressure drop. On a pressure start it must be set to remain
on long enough for the pressure to rise above the pressure that is set on the pressure setting dial (2).
9
FLOW SENSITIVITY ADJUSTMENT
Under this dust cap is a screw that sets the sensitivity of the F40 to flow. As supplied, this screw is wound fully in which is its least
sensitive position. By winding this screw anti-clockwise (out) the F40 can be set to detect progressively lower flows. In other words
become more sensitive and responsive to low flows. The screw should not be wound out beyond where the dust cap can be refitted.
The F40 will not operate if this screw is fully removed. Use a wide bladed screwdriver to adjust this screw.
10
PADDLE
The paddle (a replaceable item) must be trimmed to suit the intended application. Normally the paddle is cut so when installed it
intrudes to a little past the centre line of the pipe. The more area of paddle exposed to the flow the more responsive the F40 will be. The
paddle is normally trimmed with a pair of tin snips or a hacksaw. It can be narrowed down and its end rounded to suit the specific pipe
in which it is to be installed. The paddle should always be trimmed so there is a minimum of 4mm clearance to the closest adjacent
pipe walls. If you know the likely flow rate and the pipe size of your pump system there is an online calculator available at www.kelco.
com.au that will help you to work out an exact size to cut the paddle.
TYPICAL LARGE PUMP SYSTEM
CONTROLLED BY AN F40
PUMP
RUN-ON TIMER
AIR CELL
F40 DIGITAL PUMP
CONTROLLER
BLEED VALVE
ISOLATION
VALVE
ISOLATION VALVE
SUCTION PIPE
The run-on timer can be set to suit the specific application, for example, it can be set
to several minutes to pressurise long pipes or a large air cell. It will keep your pump
running for up to 5 minutes after the flow has reduced to a point below where the
paddle of the F40 can detect. Alternatively, it could also be set to only a few seconds
to simply allow the pump to ignore minor fluctuations in flow. The run-on timer only
starts when pressure has dropped to whatever pressure you have set on the pressure
dial, or the flow has essentially stopped. For example, air passing through the flow
switch would normally stop the pump due to the paddle detecting the momentary
loss of flow. The run-on timer will keep the pump running seamlessly and ignore this
loss of flow for whatever time period it is set to.
SERVICE
CHECK VALVE
BASIC OPERATION - NO TIMERS USED
With the three timer dials set to zero the F40 pump controller only responds to flow
in a basic way. It will behave like a basic on/off flow switch, it will simply turn on
and off in direct response to paddle movement. Any pump connected to it will also
start and stop in direct response to the actual flow past the paddle of the switch.
Power can be switched on to such a system and the pump will not automatically
start unless there is initially enough flow past the paddle of the F40 to actually turn
it on. This inability to automatically start is the very reason why a timer is normally
required to override the off state and start the pump. The only condition under which
such a system would automatically start would be if there was flow from some
external source, such as from an air cell or a gravity feed from an elevated water
source.
START TIMER
Setting the start timer (3) will override the off state of the F40 so that when power is
applied, your pump will start and will run for whatever time you have set on the start
timer dial. The blue light (6) will be on while the timer is running, and if correctly
set, and if there is a flow demand, flow will push the paddle (10) to its on position
before the start timer times out. Flow is indicated by the flow status light (7) turning
steady green in response to the flow. When correctly set the start timer should run
for slightly longer than the time it takes for the water flow to actuate the paddle of
the F40 and for the flow status light (7) to come on steady green.
The start timer and the run-on timer function independently of each other and are
totally flexible. For example you can set the start timer to 3 seconds, to get a pump
started, and the run-on timer to 5 minutes to run a pump on and pressurise a pipe
system or an air cell. Alternately, you could set the start timer to 3 minutes to allow
a bore pump with a self-draining riser time to fill its pipework, and you could also set
the run-on timer to 3 seconds to ignore bubbles of entrained gas in the pipe system.
Note that the run on period will only commence when the flow has reduced to a
lower rate than the F40 is able to detect.
STOP TIMER
The stop timer sets how long the pump remains off once it has been run dry. It can
be set on zero or from 1 minute to 48 hours in 15 steps. The stop timer can be set
for sufficient time for the standing water level in a bore to recover. At the end of the
stop time the pump will automatically restart under the control of the F40. By using
the loss of pressure as detected by the F40 when a pump is run dry, a bore pump
can be cycled and a low yield bore pumped to its maximum yield. The alarm (7) will
turn a steady red whenever the stop timer is running. This is to indicate to you that
while the pump is off it will restart automatically at the end of whatever time is set
on the stop time dial.
MAINTAINING PRESSURE IN
PIPE SYSTEMS
It is often highly desirable to maintain pressure in pipe systems, for example in a
stock watering system where long runs of pipe are involved and draw off at the
stock troughs is highly variable. Controlling a pressure pump in such systems can
be very difficult. A pump under the control of an F40 can be set to start on pressure
drop when a remote float valve opens and run while ever there is a flow demand and
then automatically stop when the flow demand ceases. The F40 will then monitor
the pressure and restart the system whenever the pressure drops again. In such a
system air cell pressure or simply line pressure is lost as stock drink. Often this
slight drop in pressure is too low to be detected by a normal pressure switch. An
F40 can automatically start the pump and run it for however long it takes for the
line to pressurise and for the flow to stop. This may take hours or minutes and may
vary considerably from time to time. If for any reason flow is lost while the pump is
running this will be detected by the F40 and the pump will be shut down. The pump
will then attempt to restart and repeat the whole process after waiting for whatever
time the stop timer has been set to.
A PUMP SYSTEM
WITH NO AIR CELL
CONTROLLED
BY AN F40
F40 INSTALLED
BEFORE THE
AIR CELL
(SEE TEXT)
DISCHARGE
PRESSURE SYSTEMS
The F40 pump controller can be used to protect a conventional pressure start
pressure stop pump from running dry if flow is lost. In a conventional pressure
system a pressure switch turns the pump on when the pressure drops and switches
it off when the pressure rises. All such systems have one basic flaw, if they run out
of water for any reason the lack of pressure will hold the pressure switch on and
keep the pump running. The result is usually severe damage to the pump. The F40
is an ideal alternative because it monitors flow as well as pressure and will stop the
pump from running dry by detecting the loss of flow. The pump will switch on on a
falling pressure and switch off when flow ceases.
AIR CELL AND PUMP STARTS
AIR CELL
F40 PUMP
CONTROLLER
PUMP
SUCTION
F40 INSTALLED
AFTER THE
AIR CELL
(SEE TEXT)
AIR CELL
An air cell is not essential in a pump system controlled by an F40.
An air cell can be used in a pump system to store pressure energy and provide the
motive power to trigger the system and restart the pump. The F40 relies on either
pressure drop or flow to start a pump. If an F40 is installed in a pump system before
the air cell, any demand at the tap will be met by the draw off from the air cell until
the pressure falls to the level set on the F40’s pressure dial. The pump will then start
and if there is an on going demand continue to pump. In such a system the draw
off capacity of the air cell and the flow demand will determine how frequently the
pump starts. A large capacity air cell will reduce the frequency of starting and thus
the cycling of the pump. A small draw off air cell will give a more constant pressure
but at the expense of more frequent starting.
If the F40 is installed after the air cell, any more than a slight flow from the air cell
will start the pump on flow. If the flow demand is extremely low, eventually the pump
will simply start on pressure drop once the pressure reaches the pressure dials set
point. Where a system is required to supply a constant pressure the F40 should be
mounted after the air cell. When pump cycling is to be kept to a minimum, the F40
should be mounted before the air cell and a large draw off capacity air cell should
be used in the system.
F40 PUMP
CONTROLLER
PUMP
DISCHARGE
SUCTION
SUBMERSIBLE
BORE PUMP
CONTROLLED
BY AN F40
F40 DIGITAL PUMP
CONTROLLER
DISCHARGE
PUMP
SENSITIVITY ADJUSTMENT
A sensitivity adjusting screw (9) is provided for fine-tuning the F40. Under the end of
the switch housing is a hex-headed plug that covers the adjusting screw. Remove the
plug and using a broad-bladed screwdriver wind the adjusting screw anticlockwise
to increase the sensitivity (reduce the flow rate needed to actuate the paddle.) As
supplied, the screw is wound fully in and the F40 is set to its least sensitive. The
maximum sensitivity is reached with the screw wound out to a point where the hex
dust cover can still be refitted. Normally the sensitivity screw should be left fully in.
If the paddle has been trimmed too short the resultant loss of sensitivity can be offset
by winding the sensitivity screw out a few turns.
LIMITATIONS
The mains voltage F40 pump controller requires a stable 220 to 240 V AC 50Hz
supply in order to operate properly. Where large pumps are connected to an F40
care should be taken to ensure cable sizes are adequate. Never use the F40 with
long or coiled extension leads or on generator sets. The electronics built into the
F40 are protected against surges and brownout and these protection systems can be
triggered by voltage drop, severe voltage spikes, or by an erratic electrical supply.
The F40 should only be used in ambient temperature water applications. It is neither
designed for, nor is it intended to be used with liquids other than water. The F40
pump controller must never be used in hot water applications (greater that 60ºC) and
must also be protected from freezing.
The standard F40-10 is designed to withstand water pressures up to 20 Bars, (300
psi) and must not be used in applications where either the static or dynamic pressure
exceeds this rating.
WARNING
If the F40 Pump Controller is used in a manner not specified by
the manufacturer the protection provided by the device may be
impaired or negated. In addition all warranties stated or implied
will be rendered invalid.
MADE IN AUSTRALIA BY
KELCO Engineering Pty Ltd
ABN 20 002 834 844
Head Office and Factory: 9/9 Powells Road BROOKVALE 2100 AUSTRALIA
Postal Address: PO Box 496 BROOKVALE NSW 2100
Phone: +61 2 99056425 Fax: +61 2 99056420
Email: [email protected] Web: www.kelco.com.au
PLEASE NOTE: The Kelco F40 Digital Pump Controller is the subject of Australian and international patent and trademark applications.
Kelco Engineering Pty Ltd reserves the right to change the specification 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 © 2010