INTRODUCTION WARNING S!!! VOC SHOULD BE BETWEEN MUST NOT EXCEED 96 VOC USE DC CIRCUIT BREAKER/ISOLATOR BETWEEN SOLAR PANELS & CONTROLLER

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2 INTRODUCTION Thank you for purchasing a WATERBOY pumping system. We set the standard for quality and economy in solar pumping. The WATERBOY range incorporates the best solar pump technologies that were very expensive until NOW!!! The WATERBOY Solar Pool Pump consists of a brushless DC (Direct Current) motor that is nearly twice as efficient as an AC (Alternating Current) motor, which means the job of filtering with DC power can be achieved with a much smaller motor. A brushless DC motor will generally outlast its AC equivalents life by up to 2 to 3 times. During the summer swimming season, your pool requires more pumping, and naturally, with more hours of sunlight, your solar pool pump will put in the work needed to keep your pool sparkling. The system is so efficient that it will continue to run even on partially cloudy days. Before you start 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 on the back page. This contains the most essential information so you can easily communicate with our support team if any problems occur. POST, FAX OR A COPY OF THE REPORT TO BW SOLAR TO ACTIVATE YOUR WARRANTY. WARNING S!!! VOC SHOULD BE BETWEEN MUST NOT EXCEED 96 VOC SOLAR ARRAY SHOULD BE 650W MINIMUM DO NOT RUN DRY AT ANY TIME USE DC CIRCUIT BREAKER/ISOLATOR BETWEEN SOLAR PANELS & CONTROLLER DO NOT TURN ON CONTROLLER UNLESS PUMP IS CONNECTED 2

3 INSTALLATION We recommend that our DC pump is installed alongside your current AC pump so that if you decide to backwash or vacuum your pool in the late evening when the sun is low/down you can simply change the valves from the DC pump back to your existing AC pump. 1. Locate the pump on solid level ground and make sure it is protected from the weather and pool splash. Water should not come in contact with the motor. Ensure there is sufficient space from other objects to allow cooling airflow from the fan. 2. If the pump is located below the water level then isolation valves will need to be installed. 3. For gluing pipes ensure correct pressure pipe priming fluid and solvent cement is used as per the manufacturers instructions. 4. Mount the controller securely in a ventilated area out of direct sunlight or rain. The controller should be placed at a good working height and protected from contact by pets or children. Ensure that safety devices such as circuit breakers protect you from making Live connections. Make sure that all connections are tight, with no loose wires. 5. Solar panels should be installed facing north and if possible, at the same angle as the latitude of the location. E.g. Perth, WA is 32 S. In northern hemisphere, panels should face south. 3

4 CONTROLLER CONNECTION! Controller has an open circuit max of 96 V DC Power Running MPPT Well Tank ON/OFF Switch DC Isolator Sample: 2 in Series, Parallel Configuration *Check what configuration your system requires 4

5 CONTROLLER CONNECTION 1. Make sure that the power switch on the side of the controller is in the OFF position. 2. Plug the pump cable coupling into the matching coupling that is on the cable that comes out of the middle of the base of the controller. Tighten the threaded coupling cover to secure connection. 3. Make sure that solar array circuit breaker/dc isolator is OFF before attempting to connect the array to the controller. Connect the +ve and ve leads, that pass through the DC isolator, from the array to the corresponding plug and play connectors that come out of the left side of the base of the controller. 4. Do not open controller as you may damage the electronics or wiring. 5. Do not turn the pump controller on unless the pump is connected and the pump is primed. On initial startup check pump rotation. See page Switch the DC isolator on before switching the pump controller on. Always turn the pump off and the DC isolator off before touching any of the wiring attached to the pump, controller or DC isolator. EARTHING AND LIGHTNING PROTECTION Surges induced by lightning are 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. CHECK WITH LOCAL AUTHORITIES ON LIGHTNING PROTECTION 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 40 volts or more. Under Australian electrical regulations an unlicensed person cannot handle voltages above 50 volts AC or 120 volts DC. Good practice will be to isolate the modules when working on or near the solar pumping system array. A simple precaution would be to throw a blanket over the solar panel array. IF IN DOUBT DON T TOUCH ANYTHING, CALL A LICENSED ELECTRICIAN 5

6 SIZING THE SOLAR PANEL ARRAY TO SUIT THE SYSTEM If you have not purchased a complete system from your supplier the following formulae will be useful. Your pump supplier will be able to help you with panel selection. The optimum loaded DC voltage (Vmp) for the solar controller is between 60VDC to 80VDC. The maximum open circuit voltage (Voc) is 96VDC. CONNECTION OF SOLAR PANELS WITH TOTAL OPEN CIRCUIT VOLTAGE OF 96VDC OR HIGHER WILL VOID WARRANTY. The Voc rating of a panel is shown on the panel label. a. Solar PV panel (solar panel) selection: Recommended Power of PV panels (watts) = Rated power of pump (watts) x 1. 3 ~ 1.6. E.g. A 500 watt pump needs a minimum of 650 watts of PV panels to drive it (500w x 1.3 = 650w) b. You may need combinations of series and parallel connections of panels, especially for the larger pumps. The required voltage is achieved by connecting the solar panels in series (series string). The total power requirement (watts) is achieved by connecting further series strings in parallel. Panels in series; add the voltage and the wattage of the panels. E.g. 2 x 12 volt, 8 Amp 100 watt panels in series become a 24 volt 8 Amp 200 watt system. Panels in parallel; add the current and the wattage of the panels. E.g. 2 x 12 volt, 8 Amp 100 watt panels in parallel become a 12 volt 16 Amp 200 watt system. Rated Voltage Rated Current Max open circuit voltage Voltage Current Max Power Dimension Weight Under Voltage Best Working Voltage Overload Over current Ambient Temperature Adaptive Peak Voltage 72VDC 15A 96VDC 1000W 42.0±0.2VDC 68±0.2VDC 18A 22A 147*232*65mm 1.10kg -20 C +50 C 35-36VDC 6

7 SOLAR CONTROLLER Function and display of the solar pump controller: a. Low-voltage protection (automatic) b. Over current protection (automatic) c. Control of motor running speed (speed regulator) d. MPPT function (Maximum Power Point Tracking) The row of LED's at the top of the controller have the following meanings L.E.D Operation Explanation Power Solar Power Green - Power is within specification Running MPPT Power is going to pump Maximum Power Point Tracking Green - Pump Running condition starts 6 seconds after Power L.E.D status is Green. Green - The Controller is calculating the MPP NOTE. The Well L.E.D. can indicate that there is not enough sunlight to run the pump and Tank L.E.D. is not used in swimming pool applications. TESTING THE PUMP Once all connections to controller and the pump are complete, and voltages and polarity have been confirmed, FILL LEAF BASKET reservoir with water and then the pump can be started: Switch on DC isolator. Press switch on side of controller to turn on. The pump has a soft start function and will start slowly after 6 seconds and then spin up to full speed within the next 6 seconds, if sunlight is strong enough. NOTE: Looking at the motor from the back (fan end) the motor should spin clockwise. Do not allow the pump to rotate anticlockwise or the pump and / or motor will be damaged and warranty will be void. If the motor spins backwards, turn everything off and call for service advice. 7

8 COMMON PROBLEMS If the pump is not delivering the required volume, or not pumping at all, the following is a checklist to diagnose the problem. Measure flow and compare with commissioning report Check & clean solar modules Check array angle Check for shading (early morning and evening in particular) Check input voltage (from modules). Input VOC should be between 78 and 95VOC Check pressure gauge readings on your filter 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 and the coupling joining the cable. Examine pump water lines for a blockage sand, tree roots, snakes, algae, etc Examine pool pipe system for breaks/leaks. Check for mechanical damage or wear, corrosion, or broken pump shaft (motor fan turns but no sound of pump turning) Examine Check Valves are they functioning correctly 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 a totally enclosed, fan cooled, brushless DC motor with no user serviceable parts. Customer should send complete unit to service centre if there appear to be any problems. Keep motor protected from excessive dirt, moisture, salt air or pool chemicals. Pump end: The pump mechanism (pump end) is lubricated only by water and requires no routine maintenance. It may wear after some years, especially if there are abrasive solids in the water. If sand accumulates in the pool, check your filtration system immediately and get it repaired before it causes damage to the pump components. Solar array mounting bolts: Bolts tend to loosen as the array structure flexes in high winds. Check tightness. Using lock washers helps 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. 8

9 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 unless they are a sealed type, check mounting hardware is secure and that the linear actuator mechanism works smoothly. 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 over. Check for damage caused by birds or other animals. NOTE: Keep pipe lengths and cable lengths as short as possible. VOC should be between 78 and 95. Must not exceed 96 VOC. Use DC circuit breaker/isolator between panels and controller. Prime pump prior to starting. DO NOT RUN DRY. Do not turn on controller unless pump is connected. Solar array should be 650W minimum. 9

10 SYSTEM REPORT Purchase Date: Dealer Contact Details: Installation Date: Installer Contact Details: Pump Model Number: Motor S/N: Controller S/N: System Voltage: Solar Panel Brand: Solar Panel Model Number/ Wattage: Quantity of Solar Panels: Solar Panel Connection: 10