SOLARJACK SDS Manuel utilisateur

SDS SERIES

DC SUBMERISIBLE PUMPS

INSTALLATION MANUAL

Kyocera Solar, Inc. / SOLARJACK, 7812 E. Acoma Drive, Scottsdale, AZ 85260

Telephone (800) 223-9580 FAX (480) 483-6431

E-mail [email protected]

www.kyocerasolar.com

12/06/99 2

Section 1

NOTE: Read sections 2 and 3 carefully before attempting to install this pump.

Improper installation will void your warranty.

SOLARJACK’S SDS SERIES DC SUBMERSIBLE PUMPS

SOLARJACK’S SDS SERIES PUMPS are positive displacement, low voltage, DC powered,

submersible pumps. Constructed of high quality marine bronze and stainless

steel, these pumps were designed for corrosion free service in clean potable

water.

They can be installed in a well, cistern, lake, or stream. If used in

conjunction with a pressure switch and tank, they may be used to pressurize a

water system.

The SDS-D series pump's light weight, only 14 pounds, and small size 3.8”

outside diameter and 10.75” length allows easy installation by hand into a 4”

inside diameter well. The SDS-Q series pump, weighing 16.5 pounds and with a

4.3” outside diameter, also allows easy installation by hand into a 5” inside

diameter well.

Their stand-alone, pollution free and low noise operation makes them an ideal

solution for remote home, wildlife, and stock watering problems, without

violating the environment.

Simplicity is the key feature of the SDS series pump line. They require no

lubrication, they run on 12 volts or 24 volts DC and are completely serviceable.

A variety of power sources may be used including solar panels, wind generator,

batteries, or any combination of the three. (A SOLARJACK PC or PB series

controller must be used as an interface between the power source and the pump on

all systems).

All new generation SDS series pumps are designed to meet the National Electric

Code. The necessary changes have been made to all SOLARJACK pumps and

controllers to meet this code.

Section 2

INSTALLATION INSTRUCTIONS

2.1 PUMP

2.la Before installing the pump, measure the depth and static water level of the

well. The static water level is the distance from the top of the casing to the

water level in the well. This information is necessary in determining where to

set the pump and the low water cut-off electrodes, if used.

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2.lb Connect the drop pipe, safety rope, and sand shroud (if used) to the pump.

Splice the drop wire to the motor lead and stretch it all out on the ground. See

the wire splicing instructions in section 2.3 (Be careful not to get any dirt

inside the drop pipe when stretching it out on the ground). If a saw is used to

cut the drop pipe, make sure to clean the saw cuttings out of the pipe before

Installation). Make the length of the pipe assembly a minimum of two feet longer

than that of the static water level plus the anticipated draw down of the water

level in the well. Never install the pump deeper than necessary.

2.lc Tie the drop pipe, drop wire, and safety rope together every ten feet with

the wire ties or a high quality black electrical tape. (If the low water cut-off

circuit- is used, attach the E-lS electrodes at the proper set points at this

time also). Slide the well seal over the discharge end of the pipe, connect the

discharge fitting, pull the drop wire through the seal, and connect the safety

rope to the I-Bolt.

2.ld Lower the pump and pipe assembly into the well positioning the well seal

over the top of the casing.

2.le Connect the discharge pipe to the fitting on top of the well seal and

attach the pump wires and electrode wires (if used) to the controller.

2.2 PANEL SUPPORT STRUCTURE

2.2a The panel support structure should be located as close to the well as

possible. This keeps the length of the drop wire and thus the voltage drop to a

minimum. It must also be mounted in a good sunlight location away from trees,

buildings, or anything that could cast a shadow on the panels.

2.2b Dig an 8” to 10” diameter hole to a depth of at least 24 inches. (This is

for a 2-module support structure.)

2.2c Install the support structure pipe into the hole making sure that the pipe

is plumb and then fill the hole with concrete. Allow 24 hours for the concrete

to cure before installing the panels.

2.2d After the concrete has cured, install the panel support head (B) on the

support structure pipe (E). Attach the upright (C) onto the head using the 5/8”

bolt tabs (A). Attach the cross pieces (D) onto the upright using the 3/8”

bolts. Attach the panels onto the cross pieces using the 1/4” bolts. (See

separate instructions for other types of support structures and trackers.)

2.2e Cover the panels with a blanket or opaque material before wiring the panels

to the controller and pump. CAUTION: PV PANELS GENERATE DC ELECTRICITY WHEN

EXPOSED TO SUNLIGHT.

2.2-f Connect the panels and controller as illustrated in the wiring diagrams in

the controller manual.

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2.2g Remove the blanket from the panels and turn the switch on. If there is good

sunlight the pump will start operating.

2.3 WIRE SPLICING

2.3a Prepare the cable by stripping the outer jacket insulation back 1-1/2” on

the pump end and 2-1/2” on the incoming power end. (The insulation on the outer

jacket of the long side is stripped back just enough to allow the smaller shrink

tube to fit over the inner wire and allow the compression sleeve to be

installed).

2.3b Prepare the inner wire ends by stripping the insulation to expose about

1/4” of each conductor.

2.3c Slip the large length of tubing over the entire cable and the smaller

tubing over each wire on the long side. Splice the wires to the motor pigtail

using the proper crimping tool and compression sleeves. Observe the color-

coding.

2.3d Position the small shrink tubing over each joint, making sure it is

centered. Apply heat to the shrink tubing with a flame from a lighter or a

propane torch. If using a torch, keep the flame moving to prevent burning the

tubing. Proper shrinkage is reached when the tubing does not show any further

reduction in size and the sealant has started to ooze at the ends.

2.3e Position the large shrink tubing over the entire joint making sure it is

positioned over each side of the outer wire jacket. Apply heat until the proper

shrinkage is reached.

2.3f To check proper sealing of the splice and wire installation immerse the

splice and wire in a container of water for ten minutes and then take a

resistance reading between the water and each of the cable conductors. Connect

one ohmmeter lead to the conductor and the other lead to a piece of metal

immersed- in the same water. Set the ohmmeter on the R x IOOK scale. The

resistance should be two megohms (2 million ohms) or higher. A lower resistance

indicates an insulation leak that must be corrected.

2.4 CONTROLLER ADJUSTING PROCEDURE

NOTE: It is usually not necessary to adjust the controller since it has been

pre-adjusted at the factory.

2.4a This procedure should be performed with the panels at their normal

operating temperature at mid-day. To maintain peak output throughout the year,

readjust the controller in very hot and very cold weather or as necessary.

2.4b With the system installed and pumping water, turn the panels away from the

sun or cover the panels until the pump flow rate is reduced by approximately

50%.

2.4c Connect a DC volt-meter to the pump side of the controller. (LD+ and LD-)

2.4d Turn the "panel voltage adjusting pot", located on the upper left side of

the controller, until the highest possible voltage is obtained. (This will also

be the highest flow rate).

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2.4e Return the panels to their normal position. The pump will then operate at

its maximum output.

2.5 ELECTRODE INSTALLATION (OPTION)

2.5a With the pump and pipe stretched out on the ground and before installation

into the well, (refer to step 2.1b) cut the electrode wire to the desired

lengths and install all three E1-S electrodes in the proper locations.

2.5b The "ground electrode", terminal 3, must be in the water at all times and

should be placed approximately two inches above the top of the pump. The "low

water level electrode" terminal 1, is placed at the desired cut off point and is

usually placed two to six inches above the ground electrode. The "high water

level electrode", terminal 2, is placed at the desired turn-on level, but must

be placed below the static water level and should be located no more than 20

feet from the low water electrode.

NOTE: Wells with a high mineral content in the water and/or with cascading water

above the electrodes may not be suitable for use with the low water cut-off

circuit. Mineral deposits may collect on the electrodes insulating the circuits

from the water.

Section 3

FOR PROPER PUMP PERFORMANCE

(Do not disassemble the pump during the warranty period. Any tampering will void

your warranty). WARNING: IF THE PUMP IS DISASSEMBLED, USE EXTREME CAUTION AS THE

MOTOR HOUSING MAY BE UNDER HIGH PRESSURE.

3.la For optimum pump performance make sure that the wire is sized properly for

the length of run between the pump and the panels. Wire sized too small will

cause a decreased output from the pump. Keep the distance from the PV panels to

the pump as short as possible. For depths over 150 feet, higher wattage panels

will help compensate for the additional losses in the longer wire lengths as

well as the higher current requirements.

3.lb Make sure that the discharge pipe is sized properly for the length of run.

Friction loss in a pipeline, especially over a long distance, will add head to

the pump and thus reduce the flow rate. (Consult your SOLARJACK dealer for

correct sizing for your system).

3.lc Never rest the pump on the bottom of the well, lake, cistern, etc. This can

cause the pump to fill with mud and damage the diaphragm as well as reduce the

flow of water past the motor and may cause overheating problems. Suspend the

pump five feet or more above the bottom of the well.

3. 1d Use no larger than 1/2” drop pipe on SDS-D series pumps and 3/4” on SDS-Q

series pumps. Because of the low flow rates the velocity of the water in larger

pipes is not fast enough to carry small particles to the surface. These

particles may settle inside the pump as well as the drop pipe causing pump

damage as well as restricting the flow of water. If there is a known sand

problem, a sand shroud or a screen is required. (Please note that the minimum

well casing diameter for the SDS-D series shroud is 5” and the SDS-Q series

shroud is 6”). Damage to the pump caused by sand will void your warranty. It is

12/06/99 6

highly recommended that all pumps be installed with sand shrouds for maximum

pump protection.

3.le Due to the aggressive action of DC power, it is essential that the wire

splice at the pump be made correctly. This splice must be watertight. Improper

sealing of this splice will cause poor pump performance and may cause damage to

the controller. SOLARJACK’S splice kit #S-703 is recommended for this watertight

connection.

3.lf Never install the pump over 60 feet below the static water level. Excessive

water pressure on the pump may cause seal damage and allow water to enter the

motor housing.

3. 1g Never chlorinate a well while the pump is installed. Heavy concentrations

of chlorine will damage the diaphragm and seals.

3.lh Never install the pump in a well that has or has had an oil lubricated line

shaft turbine in it. Any drip oil remaining in the well will damage the

diaphragm and seals.

3.li If the pump is used in a well over l00 feet deep, install a poppet type

check valve on top of the pump. This will help relieve some of the pressure on

the internal check valves and will keep any sediments from falling back into the

pump.

Section 4

TROUBLESHOOTING

4.1 PUMP DOES NOT RUN

4.la Check wiring diagrams for proper connections.

4.lb Check for proper panel, controller, and/or battery voltage

with a volt meter. If our pump controller is being used, a quick look at the

indicator lights will verify power coming from the panels going to the

controller and power coming from the controller going to the pump. If the red

light is on and the green light is not, connect a jumper wire across terminals 6

(PV-) and 7 (LD-). This will bypass the controller and will allow the pump to

run panel direct.

4.lc Check the splice above the pump for proper connections.

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4.ld Check for a broken wire leading to the pump.

4.le Check to see if the water level is above the top electrode, if the low

water cut-off circuit is being used. (Turn dip switch #5 off and switch #6 on to

bypass the low water cut-off circuit.)

4.lf Check for an open motor winding. (With an ohmmeter set on the R x 1 scale

check between the two pump wires. Meter reading should be between .5 and 50

ohms. If the resistance is higher than this, disconnect the pump at the splice

above the pump and check again).

4.lg Check the controller for proper adjustment. If the controller is adjusted

wrong the pump flow rate will be low. If the voltage setting is higher than the

input voltage, the controller will not turn on. (See section 2.4)

4.lh Check to see if the float switch, if used, is functioning properly.

(Disconnect wires from terminals 4 & 5 to bypass the float circuit).

4.2 PUMP RUNS BUT DOES NOT PUMP WATER

4.2a Check to see if the pump is below the surface of the water. 4.2b Check for

holes in the drop pipe.

4.2c Check for a plugged suction screen or pump full of mud, sand, or pipe

cuttings. (If the pump is full of mud or sand, hold the pump upside down in a

bucket of water and allow it to pump until all the mud clears).

4.2d Check for a plugged drop pipe or discharge pipe.

4.2e Check to see if the controller is adjusted properly. (See controller

adjusting procedure section 2.4)

4.3 EXCESSIVE CURRENT DRAW (Over the normal amperage rating of the pump).

4.3a Check wiring diagrams for proper connections.

4.3b Check for skinned wires or faulty underwater splice. (See section. 2. 3d)

4.3c Check for a locked motor armature. (With the pump out of the well, bypass

the controller and connect power directly to the motor leads. If the pump still

does not run and the current is over 1.5 amps, the pump is in a locked or loaded

rotor condition and must be repaired).

NOTE: New pumps will draw slightly higher current for approximately 30 days.

With the new heavy duty bearings and long life brushes the pump goes through a

longer break-in period.

12/06/99 8

4.4 DECREASED PUMP OUTPUT

4.4a Check for a plugged suction screen. (Pull the pump and clean the screen).

4.4b Check for holes in the drop pipe.

4.4c Check for a restriction in the drop pipe.

4.4d Check to see if the water level in the well has dropped lower than normal

or below the pump.

4.4e Check for mud or sand packed inside the pump or drop pipe. (If the pump is

full of mud or sand, hold the pump upside down in a bucket of water and allow it

to pump until all the mud clears. If the pipe is plugged with sand, clean the

sand out of the pipe and install a SOLARJACK sand shroud around your pump).

4.4f Check the controller for proper adjustment. A controller being out of

adjustment will cause decreased flow rates. (See section 2.4)

4.4g Check for the correct pump motor polarity. The black motor lead is always

negative and the red motor lead is always positive. If these leads are reversed

increased motor current and decreased pump flow rates will occur.

4.4h Check for dirt on the array or partial shadowing of the array.

4.5 PUMP RAPID CYCLING

4.5a If the low water cut-off circuit or high water cut-off circuit is being

used, check to see if the high and low electrodes have been reversed.

4.5b If a pressure switch is being used, make sure a pressure tank is installed.

4.5c If a pressure tank is being used, make sure the tank is not water logged.

4.5d If a diaphragm pressure tank is being used, make sure the air pressure in

the tank is 2 pounds less than the cut-in pressure, with the tank empty.

WARNING: IF THE PUMP IS DISASSEMBLED USE EXTREME CAUTION AS THE MOTOR HOUSING

MAY BE UNDER HIGH PRESSURE. REMEMBER, THIS VOIDS All WARRANTY.

12/06/99 9

12/06/99 10

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