2
CONTENTS INTRODUCTION ....................................................................................................................................... 2
INSTALLATION ......................................................................................................................................... 4
SOLAR ARRAY INSTALLATION .................................................................................................................. 5
SEASONAL ADJUSTMENT ........................................................................................................................ 5
INSTALLATION IN A OPEN WATER SOURCE ............................................................................................ 6
INSTALLING THE PUMP UNDER A WINDMILL OR HAND PUMP CYLINDER ............................................. 6
SPLICING THE SUBMERSIBLE PUMP CABLE ONTO THE SUBMERSIBLE MOTOR. .................................... 6
INSTALLATION OF THE WATER LEVEL SENSOR ....................................................................................... 7
CONNECTING THE CONTROLLER ............................................................................................................. 8
METHOD .................................................................................................................................................. 9
FOREWARNINGS ................................................................................................................................... 10
WARNING FOR SIPHON APPLICATIONS ................................................................................................ 10
SPEED ADJUSTMENT ............................................................................................................................. 11
EARTHING AND LIGHTNING PROTECTION ............................................................................................ 11
TROUBLESHOOTING .............................................................................................................................. 12
RUNNING INDICATORS AND MALFUNCTION INFORMATION ............................................................... 12
COMMON COMPLICATIONS ................................................................................................................. 14
MAINTENANCE ...................................................................................................................................... 16
SYSTEM REPORT .................................................................................................................................... 17
NOTES.................................................................................................................................................... 18
Find us at: www.bwsolar.com.au
3
INTRODUCTION
Thank you for purchasing a WATERBOY pumping system. We set the standard for quality and
economy in solar pumping solutions. The WATERBOY range incorporates the best solar pump
technologies that were very expensive until now.
Before you start, please check the model numbers of all the components of your system and
verify that they are the items that you ordered.
Check against the pump specifications and performance charts to be sure the system is
appropriate for your application.
If you think you may have the wrong pump system for your application, call your supplier
immediately.
Please fill in the system report. This contains the most essential information so you can easily
communicate with our support team if any problems occur.
4
INSTALLATION
Lay the pump with cable along the ground from the top of the bore, so that the pump is
at the bore end, then lay the pipe and block the ends of the pipe so that no stones, dirt
or gravel can enter the ends of the pipe and lay the pipe along the ground along-side the
submersible electrical cable and pump. It is very important that you don’t kink or bend
the poly (if using poly pipe) as this can result in the poly splitting later. Connect the bore
pump to the pipe and or bore cap using appropriately rated pipe fittings. Lay the water
level monitoring probe (if needed) next to the pipe, then tape the power cable and probe
cable to the delivery pipe every 2 meters to prevent snarling of cable. Be sure to leave
slack between each section of tape when using poly as it will stretch, and use a strong
tape such as duct tape.
You should now have, the pipe, power cable and probe cable taped together, bundled
and laid out on the ground. Not taped, but laying alongside them is the safety cable.
MAKE SURE THE SAFETY SUPPORT CABLE IS CONNECTED TO THE BORE CAP AND
SECURED. The combination of the pump, pipe, cable, probes and safety cable can now be
carefully lowered into the bore taking care not to cut or chafe the cable insulation on the
bore casing. Lower the pump into the bore slowly without force to approximately 3
metres below maximum water draw down and if possible 3 metres from the bottom of
the bore. Make sure the poly doesn't kink at all when lowering it into the bore as it may
possibly cause the poly to split later when under pressure. Pull on the bore pump
support cable so the weight of the pump is on the cable and then fasten it.
5
SOLAR ARRAY INSTALLATION
There are two ways to install the solar array.
1. Assemble the array on the ground, and then lift the entire assembly onto the pole or roof. A
system of 300 W or more may require the assistance of a backhoe, boom truck or crane to lift it over
the pole.
2. Assemble the array piece-by-piece on the pole. If the pole is higher than about 6 ft (2 m), it is best
to construct a temporary platform, like a scaffold assembly commonly used in building construction.
Follow the rack (or tracker) manufacturer’s instructions that are packed with your rack. A solar
tracker is a special pole-mounted solar array rack that tilts automatically to follow the daily path of
the sun. In clear summer weather, it can increase your daily water yield by 40-50 % (It is much less
effective in winter and in cloudy weather).
SEASONAL ADJUSTMENT
At latitudes outside of the Tropics, there can be
a marked difference in pump output on a
seasonal basis partially due to the changes in the
sun’s elevation in the sky in relation to the solar
array. For systems in the southern hemisphere,
the solar array should be installed facing north
and in the northern hemisphere they should face
south. If the solar array is to be installed in a
fixed position and never adjusted (such as on a
shed roof) it is most effective throughout the
year to have it facing towards the equator and
placed at an angle from the horizontal, equal to the latitude of the installation.
Having a seasonal adjustment allows the user to change the angle of the array and can produce a
greater output from the pumping system. By having the array at a steeper angle during the winter
(when the sun is lower on the horizon) more of the sun’s rays will strike the surface of the array and
provide more power to the pump. In the summer months the angle of the array can be reduced to
take advantage of the sun’s higher position in the sky. This adjustment improves total output
whether the solar array is a fixed or a single axis tracking type.
6
INSTALLATION IN A OPEN WATER SOURCE
This refers to a dam, soak, lake, river or tank. We recommend to float the pump in a pontoon or
similar, but if this is not an option you should position the pump in an inclined position with a
minimum angle of 30°. To reduce the intake of sediment, do not place the intake of the pump very
close to the bottom of the river or dam. Secure the pump in some slotted bore casing using stainless
steel wire rope.
INSTALLING THE PUMP UNDER A WINDMILL OR HAND PUMP CYLINDER
WATERBOY pumps can be combined with a classic water-pumping windmill or hand pump, to utilize
both energy sources automatically. The following system is often used with a conventional AC pump,
so a generator can be used for backup. The AC pump is placed immediately below the cylinder, and
connected to the cylinder’s threaded intake. When power is applied to the AC pump, it pushes water
up through the cylinder, pushing its valves open. When the windmill draws water, it sucks it up
through the AC pump with little resistance. (The centrifugal pump end of the standard AC pump
allows water to flow through it when it is stopped.) When both pumps operate, each one is relieved
of its load, more or less.
This system can be employed with WATERBOY pumps. A centrifugal model will allow water to flow
freely through it and does NOT require any special precautions. For helical rotor models, the
following warning applies.
To use a helical rotor pump under a cylinder, you must build a bypass assembly with a T fitting and a
foot valve (a check valve with intake screen). When the cylinder’s flow exceeds that of the solar
pump, water is sucked in through the foot valve. When the solar pump’s flow exceeds that of the
cylinder, the foot valve closes and allows the solar pump to work normally and push up through the
cylinder. To make this system for a casing 6 in (150 mm) or smaller, an offset using 45° elbows must
be carefully constructed.
SPLICING THE SUBMERSIBLE PUMP CABLE ONTO THE SUBMERSIBLE MOTOR
Use only an approved type of submersible pump cable; the same type that is used for conventional
AC pumps but make sure that cable sizes are large enough for the system (minimum 2.5mm² or
larger for power cable). We have found rubber submersible cable to be best. A splice kit includes
crimp connectors to join the copper wires, adhesive heat-shrink tubing, and instructions. If the drop
cable is too large to fit in the crimp connector, cut off some of the wire strands. Use a crimping tool,
and observe that the wires are held very securely. Leave to cure and cool for 10 – 15 minutes before
moving the join.
7
INSTALLATION OF THE WATER LEVEL SENSOR
The two leads of the water level sensor must be connected to the right end terminal and the 3rd
terminal from the right of the controller. Refer to the diagram on the next page. The best location
for the sensor itself is to be securely attached above the discharge level of the pump (above the
check valve if one has been attached to the pump discharge). The sensor needs to be able to operate
in a vertical position and the holes which allow water to enter the sensor should not be blocked.
NOTE: If, for any reason, no water level sensor is used, a ‘jumper’ should be installed between
terminal on the right end, of the controller, and the 3rd terminal from the right.
If the pump runs dry, such as when the water level is below the pump
intake, the pump and/or motor will be damaged (voids warranty). The
purpose of the water level sensor is to prevent this happening and it
will cause the pump to shut down rather than running dry.
Once the water level recovers, the sensor will allow the pump to
restart. Within controller it is possible to adjust (lengthen/shorten) the
time that the pump takes to restart after the low level sensor is re-
submerged. This helps prevent the system from cycling on and off
constantly when the pump is pumping as fast as the water source is
recovering.
8
CONNECTING THE CONTROLLER
Mount the controller securely in a ventilated area out of direct sunlight or rain. This is often on the
south side of the post used for the north facing solar array. The controller should be placed at a good
working height, shaded by the panels and protected from contact by livestock, wild animals or
children. Ensure that safety devices such as circuit breakers protect you from making “Live”
connections. Make sure that all connections on the terminals are tight, with no loose wires.
9
METHOD
1. Set the switch in the controller to the OFF position. This is the middle position, see page 8.
2. Connect pump cable to terminals as indicated. If you find pump rotation is incorrect upon start
up, exchange any 2 of the pump lead connections with each other.
3. If the solar array has a circuit breaker/isolator make sure that it is OFF before attempting to
connect the array to the controller. Connect the +ve and –ve leads from the array to terminals
P+ and P- .
4. Connect the low level sensor leads. If no sensor is being used, connect a link between the right
end terminal and the terminal 3rd from the right.
5. Connect leads for the tank full sensor if this option is being used.
6. Turn ON the solar array circuit breaker/isolator if one is included in your system.
7. Switch the controller ON by moving the switch up from the middle position; all indicator lights
will turn on briefly and then go off except for the light on the left end marked “SYS” (System)
which should be green. After a few seconds the green “Pump” light will turn on and if all is
connected correctly the pump will now start. If the pump is not working correctly, check the
operation indicator lights and malfunction guide to find the cause or, contact the supplier.
NOTE: The green MPPT light will flash on and off during pump operation.
8. Always shut power OFF before changing any connections in the controller. Turn the solar array
circuit breaker/isolator off first, if one is included in the system, and then turn the pump
controller off.
10
FOREWARNINGS
DO NOT SCREW ANY FITTINGS TOO FAR INTO THE PUMP. YOU CAN RESTRICT THE
PUMP STATOR
DO NOT SET THE PUMP ON THE BOTTOM OF THE BORE.
MAKE SURE THERE IS A NON-RETURN VALVE INCLUDED IN THE LINE.
ALLOW THE PUMP TO SIT SUBMERGED FOR 15-20 MINUTES BEFORE ATTEMPTING
THE FIRST START UP.
DO NOT RUN DRY AT ANY TIME
ALWAYS USE THE STAINLESS STEEL CABLE TO RAISE OR LOWER THE PUMP
ASSEMBLY. DO NOT USE THIS CABLE AS AN EARTH WIRE.
LOW WATER SENSOR MUST BE INSTALLED ABOVE THE PUMP INTAKE LEVEL.
DO NOT USE THE PUMP TO CLEAN OUT A DIRTY BORE.
SAND CONCENTRATION OF GREATER THAN 0.1% BY VOLUME MAY CAUSE A
SIGNIFICANT REDUCTION IN FLOW AND/OR BLOCKAGE.
NEVER EXCEED OPEN CIRCUIT VOLTAGE RATING (Voc) OF THE CONTROLLER. FOR
24 – 48 VOLT CONTROLLERS, MAX Voc IS 100. FOR 110 VOLT CONTROLLERS, MAX
Voc IS 200.
If the power leads (drop cable) from the motor are connected incorrectly, the pump may run in
reverse producing a low flow or no flow at all. To reverse pump rotation, exchange any 2 of the leads
with each other in the controller.
If a screw (helical rotor) type pump is not going to be used for a prolonged period, remove the pump
from the water, wipe the pump body and the screw and store it in a clean dry location away from
extreme temperatures. This is to prevent the expansion of the rubber stator in the pump which
could cause the pump to seize up the next time it is to operate. It may be easier to leave the pump
submerged and just run it for an hour or so each week.
WARNING FOR SIPHON APPLICATIONS
If a pump system has a vertical lift of less than 10m up from the surface of the water source, and
then the water flows downhill to a lower point, a siphon effect may cause suction at the pump
outlet. This will cause an upward thrust on the motor shaft, resulting in damage to the motor.
Prevent this by installing an air vent or a vacuum breaker at the high point on the pipe.
11
SPEED ADJUSTMENT
Although the water level sensor protects the pump from running dry, it is possible that the system
could cycle on and off rapidly during peak sun hours when the pump gives its greatest output. By
using the low level timer delay knob in the controller, it is possible to delay the pump from restarting
as soon as the water level recovers. This prevents the rapid cycling of on and off but may mean that
your daily flow rate is lowered as you miss some of those peak sun hours.
The solution to this is to use the speed control knob. By observing the system when it is pumping at
its greatest rate during the middle of a clear summer day, you will be able to see whether the bore is
able to keep up with the pump output. If the pump is shutting off on “low level” more often than
you would like, even with the time delay being used, you may wish to reduce the speed of the
motor. Just turn the speed control knob down by twisting it, counter clockwise, a small amount. This
will lengthen the time between the shut-offs. Continue reducing the speed in small stages until you
are satisfied with the compromise between the flow rate and the amount of time that the pump
shuts off on “low level”.
EARTHING AND LIGHTNING PROTECTION
A surge induced by lightning is one of the most common causes of electronic controller failures in
solar water pumps. Damaging surges can be induced from lightning that strikes a long distance from
the system, or even between clouds. The risk of damage is greatly reduced if these instructions are
followed.
Legal expectation
CHECK with local authorities on Lightning protection
Float switch cable.
A long run of control cable to a float switch in the storage tank can pick up damaging surges from
nearby lightning. The best protection is to use shielded cable. Shielded cable has a metallic foil or
braid surrounding the two wires. Earth the cable shield at the controller end only NOT at the float
switch. This will reduce surges induced by nearby lightning. This product is suitable for direct burial,
but not for submersion in the water
Additional lightning protection is recommended under any of the following conditions:
Isolated location on high ground in a severe lightning area.
Dry, rocky, or otherwise poorly conductive soil.
Long wire run (more than 30m) from the controller to the bore head, or to the float switch.
Additional lightning protection devices (surge arrestors) may be obtained from a local
source.
12
TROUBLESHOOTING
Safety - When troubleshooting solar water pumping systems be mindful that voltages can be lethal.
With the growth in the ability and capacity of systems (from the initial small systems to today’s very
large systems) the voltage of the system has grown. A two module system, with the modules wired
in series will have an open circuit voltage of around 40 volts. Under Australian electrical regulations
an unlicensed person cannot handle voltages above 40 volts (DC or AC). Good practice will be to
isolate the modules when working on or near the solar pumping system array. A simple precaution
will be throwing a blanket over the array. IF IN DOUBT, DON’T TOUCH ANYTHING AND CALL A
LICENSED ELECTRICIAN.
RUNNING INDICATORS AND MALFUNCTION INFORMATION
The controller has a series of LED lights that indicate the system status. This information helps you
know what is happening with your system.
1. POWER or SYS light: Indicates that power is on to the system.
2. RUN or PUMP light: Indicates that the pump motor is running.
3. MPPT light: Indicates maximum power point with highest voltage and amperage.
4. ERR I light: Indicates current error. Examples are when power cables are too small (fix this by
using larger wire cross section such as 4mm² rather than 1.5mm²) or a locked rotor in the pump
(fix this by cleaning out any debris from the pump)
5. LOW POWER light: Indicates low input into controller. Check for shading or bad panel
connections.
6. TANK F light: Indicates that tank is full.
7. WELL L light: Indicates that water level has dropped and the low level sensor has turned the
pump off.
13
Malfunction Reason Solution
Power light off Power off Turn power switch on
Connection is wrong or loose Check all connections and re-tighten
Control box, solar panel or battery
faulty
Check components and repair/
replace
ERR I light on The size of the power cable is too
small (less than 1.5mm2)
Use a heavier duty power cable,
larger than 1.5mm2
Motor in locked rotor condition Remove any debris blocking motor or
pump.
Pump submerged too far below
water level.
Raise the pump closer to the water
surface.
Low Power light
on
Sunlight not strong enough. Wait until sunlight level increases, or
remove items shading array.
Loose connection in solar array or
damaged panel.
Check all connections between
panels and to the controller. Replace
damaged panel(s).
Well L light on The water level is too low and low
level sensor has turned pump off.
Wait for the water level to recover in
the bore.
No low water level sensor installed Install a low water level sensor as per
the instruction manual. If no sensor
is required, install a jumper wire
between right end terminal &
terminal 3rd from right. (See page 8)
14
COMMON COMPLICATIONS
If the pump is not delivering the required volume, or not pumping at all, the following is a checklist
to diagnose the problem. Use the following “Diagnosis of Solar Pumping Problems”
Measure Flow and compare with Commissioning Report
Check & Clean Modules
Check Array Angle
Check for Shading (early morning and evening in particular)
Check input Voltage (from Modules)
Check Pressure Switch / Float Switch
Check Pressure Gauge readings
Check flow with delivery pipeline disconnected
Check Suction Height
Check for broken or burnt cells on the modules.
If the pump doesn’t work at all, check the following,
Carefully check the Electric Cable to the Motor. Especially check any underwater cable splice.
Check the Pressure Switch/ Float Switch is operating.
Disable the Pressure Switch/ Float Switch and retry starting the Motor (Use care when
disabling – ensure that the Controller is turned off)
Examine pump for a blockage – sand, tree roots, snakes, algae, etc
Check the Bore has an adequate water supply.
If the pump has a suction head – Check the height from the water to the pump.
Dismantle Pump and check for wear – a worn helical rotor will pump some water at low head,
but the flow will die once the head is increased.
Examine pump, check for corrosion, erosion, and broken pump shaft.
Examine Check Valves – are they functioning correctly?
Check the wiring from the Modules.
Coping with Dirty Water Conditions
WATERBOY pumps have good resistance to quantities of sand and fine sediment that can normally
occur in a well. However, any amount of abrasive material will reduce the life of this pump, like any
other pump. Extreme sediment can cause the pump to stick. Sediment can also settle inside the drop
pipe each time the pump stops, and block the flow. For water sources that contain high amounts of
sand, clay, or other solids, consider the following suggestions.
15
To avoid pumping dirty water
1. Have your well purged, developed, or otherwise improved by a water well contractor before
installing the pump.
2. Temporarily install a more powerful pump to draw at a high flow rate until the water looks
clean.
3. Set the pump as high as possible in the well. If the pump can be placed higher than the
perforations in the well casing, it will probably avoid all but the finest suspended silt.
4. After lowering the pump in a well, wait at least 15 minutes for sediment or debris to settle
down.
5. If the water source is at the surface, dig a shallow well next to the water source to obtain
clean water
16
MAINTENANCE
The controller is electronic with no moving or wearing parts. It requires no maintenance. There are
rubber gasket seals at the top and bottom, and rubber plugs to seal unused conduit holes. Inspect
them to insure that the controller is sealed from moisture, insects, etc. Check that mounting and
conduit hardware is tight.
Motor: The motor is oil-lubricated and requires no maintenance. It is permanently sealed and has no
brushes or other frequently wearing parts.
Pump end: The pump mechanism (pump end) is lubricated only by water and requires no
maintenance. It may wear after some years, especially if there are abrasive solids in the water. If
sand accumulates in the storage tank or pipes as a result of normal pumping, it is best to take
periodic measurement of the pump’s performance. If the flow rate is less than normal, a worn pump
end can easily be replaced, after the pump is pulled from the water source.
Solar array mounting bolts: Bolts tend to loosen as the array structure flexes in high winds. Check
tightness. All bolts should have lock washers to keep them tight.
Sun exposure: Cut away any vegetation that will grow enough to block solar illumination. Shading
even a small corner of the solar array may stop the pump, or greatly reduce its flow.
Solar array cleaning: If there is dirt, mineral deposits, bird droppings or other debris stuck to the
solar array surface, clean it with water, vinegar or glass cleaner.
Solar Tracker: If the system uses a solar tracker, lubricate the bearings, check mounting bolts and
mechanism.
Power wiring: Inspect wires and connections carefully. Any wires that are hanging loose should be
secured to prevent them from swinging in the wind. Exposed wiring must be sunlight resistant and in
good condition. In the case of a tracking array, look carefully for any wire damage due to rubbing,
bending, or pulling as the tracker swings
17
SYSTEM REPORT
Purchase Date
Dealer Contact Details
Installation Date
Installer Contact Details
Pump Model Number
Serial Number
System Voltage
V
Solar Panel Brand
Solar Panel Model Number/ Wattage
W
Quantity of Solar Panels
Bore Depth
m
Drawdown Level
m
Pump Depth
m
Vertical lift from bore head to top of tank
m
Pipe Size
mm/in
Distance to tank
m
Submersible pump cable length
m
Submersible pump cable size
mm2
18
NOTES
Rev. 0812
