BW SOLAR Waterboy User manual

Installation Manual

2
CONTENTS
INTRODUCTION.......................................................................................................................................3
INSTALLATION.........................................................................................................................................4
Bore.....................................................................................................................................................4
Dam.....................................................................................................................................................5
Other...................................................................................................................................................5
Installing the Pump under a Windmill or Hand Pump Cylinder..........................................................5
Warning for Siphon Applications ........................................................................................................5
SOLAR ARRAY..........................................................................................................................................6
Seasonal Adjustment ..........................................................................................................................6
Wiring the Array..................................................................................................................................6
Lightning Protection............................................................................................................................7
CABLE JOINING........................................................................................................................................8
Splicing the Submersible Pump Cable onto the Motor.......................................................................8
Splicing the Submersible Cable onto the Low Water Probe...............................................................8
CONNECTING THE CONTROLLER.............................................................................................................9
Wiring..................................................................................................................................................9
Speed Adjustment.............................................................................................................................10
Timer.................................................................................................................................................10
ELECTRICAL CONNECTIONS...................................................................................................................11
Wiring Diagram for Controller ..........................................................................................................11
Wiring Diagram for Solar Modules in Series.....................................................................................12
Wiring Diagram for Solar Modules in Series/Parallel (2x2) ..............................................................13
Wiring Diagram for Solar Modules in Series/Parallel on Single Array (4x2).....................................13
REMOTE SWITCHING ............................................................................................................................14
Waterboy Tank Float Switch.............................................................................................................14
Wiring............................................................................................................................................14
Waterboy Pressure Switch................................................................................................................15
Wiring............................................................................................................................................15
Setting ...........................................................................................................................................16
TROUBLESHOOTING..............................................................................................................................17
Running Indicators and Malfunction Information ............................................................................17
Controller Indicator Lights ................................................................................................................18
Common Complications....................................................................................................................20
MAINTENANCE......................................................................................................................................21
Replacing the Pump rotor and stator ...............................................................................................22
Dismantling the worn pump assembly .........................................................................................22
Inspection of parts ........................................................................................................................23
Fitting the new pump assembly....................................................................................................24
NOTES....................................................................................................................................................25
WARRANTY STATEMENT.......................................................................................................................26
www.bwsolar.com.au

3
INTRODUCTION
Thank you for purchasing a WATERBOY solar water pumping solution.
Waterboy sets the standard for quality and economy in solar powered water pumping, utilising the
very best technologies available today.
When sizing or expanding on your existing system, it is important to understand the performance
limitations of your pump, and the source to destination details required in choosing the right pump
for your job.
Please visit our website for sizing details and performance information of our products when
considering your next pump. www.bwsolar.com.au
Please fill in the System Report Form. This contains the most essential information so you can easily
communicate with our support team if any problems occur. It must be completed and returned to
activate your warranty.
Information and limitations to consider before proceeding
NEVER EXCEED OPEN CIRCUIT VOLTAGE RATING (Voc) OF THE CONTROLLER. (p11)
Ensure correct motor wiring by observing the corresponding numbers labeled. Any
incorrect wiring will cause the pump to run backwards and damage the pump. (p8)
Do not set the pump on the bottom of the bore or in / near mud and debris.
Do not exceed a maximum submersion depth of 40m at any time.
Make sure there is a non-return valve included in the line.
Do not allow the pump to run dry at any time.
Always use the stainless steel cable to raise or lower the pump assembly. (p4)
The low water sensor (when used) must be installed a minimum of 300mm above
the water inlet of the pump. (p4)
Do not use the pump to clean out a dirty bore.
A solids concentration of greater than 0.1% by volume may cause a significant
reduction in flow and/or blockage. This will void your warranty.
These pumps are designed for use with potable water only, at a water temperature
below 30⁰c.
Do not screw any fittings too far into the pump as this can restrict the pump stator.
Avoid water locking (p21)
Do not pump dirty / muddy water / sandy water, this will void your warranty.
CORROSIVE WATER
Although the pumps are made of 316 stainless steel, harsh water can cause corrosion of the pump
body and parts. This may be a function of the chemical make-up of the water or stray voltage in the
water (often from stock fences that may be quite far from the pump site). If this is found to be a
problem in your application, the use of a sacrificial anode is recommended.

4
INSTALLATION
Waterboy pumping systems are designed with simplicity in mind, to provide as trouble free an
installation as possible.
When purchased as part of a complete package it is recommended that the solar array frame
and panels be assembled prior to any pump work (see Array Frame Manual for details).
A complete package will also have the controller and any remote switching devices pre wired
for your convenience.
1. Lay the pump close to the water source and unroll the power and low water probe (if
supplied) cables to length.
2. Lay the pipe out along the pump cable ensuring that no stones, dirt or gravel can enter
(It is very important that you don’t kink or bend the pipe as this can result splitting
when under pressure).
3. Connect the pump to the delivery pipe (and bore cap if used).
4. Align the low water probe no less than 300mm above the pump water inlet level and
secure to the pipe (see Bore) or post (see Dam) in a vertical position, with the cable out
the top, using the 3 small cable ties supplied.
5. Secure the power cable and probe cable to the delivery pipe every 2 meters with a
strong tape (such as duct tape) to prevent snarling of cable. Be sure to leave some
slack between each section of tape as this will allow for the pipe to stretch.
Bore –when installing in a bore or suspending in a well you will need to use a strainer or suspension
wire for hanging the pump (we supply a 3mm 316 stainless steel cable with all our bore systems).
Connect the safety support cable to the bore cap and secure to the pump prior to positioning in the
bore or well.
Probe: Attach the low water probe to the delivery pipe no less than 300mm above the pump water
inlet in a vertical position, with the cable out the top, using the 3 small cable ties supplied.
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.
*DO NOT SUSPEND THE PUMP BY THE ELECTRICAL CABLES OR PIPING*
Lower the pump into the bore slowly without force to approximately 3 metres below the minimum
water level and if possible no less than 1 metre from the bottom of the bore. Pull on the bore pump
support cable so that most of the weight of the pump is on the cable and then remove any slack and
fasten it.

5
Dam –when installing in a dam the pump is placed into or beneath a flotation device to suspend it
in clear water. The pump is then tied to the opposite bank with a tie off rope to stop it floating
about.
Ensure the pump is tied off when in the deepest part of the dam so that it remains floating
throughout the seasonal fluctuations.
Probe: Secure the low water probe to a post (or star picket) in a vertical position, with the cable out
the top. Position the post in the dam before the determined low water mark where the pump needs
to stop pumping before entering mud and silt. Ensure the probe becomes dry before the pump.
Dam Kit –the Waterboy Dam Kit (when supplied) comes with a sturdy pump float assembly and 2
extra floats for keeping the cables and piping out of the mud and rocks at the bottom of the dam
Other - This refers to a soak, lake, river or tank. We recommend to float the pump under 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. Secure the pump in some slotted bore casing using stainless steel
wire rope.
For All applications it is recommended that a low water probe be used to avoid running the pump
dry. (p.4)
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.
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. To prevent this,
install an air vent or a vacuum breaker at the highest point in the delivery pipeline.

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SOLAR ARRAY
The solar array is the power source for your pump and should be installed as close to the pump as
possible. Always ensure the panels are free from dirt and debris and free from shading throughout
the day, even partial shading or dirt can reduce or stop your water output.
Please see the Waterboy Array Frame Manual for assembly instructions.
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.
Wiring the Array
When connecting the panels together you need to be aware of the configuration required.
*** ATTENTION! - Always be aware that solar panels are a live power source and can kill ***
Series –in this configuration the leads are connected together positive to negative in a chain (similar
to batteries in a torch), this produces a voltage equal to the sum total of all the panels but the current
remains the same as an individual panel.
Parallel –in this configuration the leads are connected positive to positive and negative to negative,
this produces a current equal to the sum total of all the panels but the voltage remains the same as
an individual panel.
This is vital to know, as the flow of water from the pump is directly related to the voltage supplied,
the higher the voltage supplied the faster the pump turns and the more water flows. Also, the more
current available to the pump the higher and further the pump can deliver water.
See configuration diagrams (pages 12 & 13)
WARNING! - be careful not to exceed the voltage limit of the controller or the power limits of the
motor. (pg. 11)

7
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.
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
Lightning rods, surge arrestors and additional lightning protection devices may be obtained from a
local supplier.
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.
Legal expectation
CHECK with local authorities on any Lightning protection obligations.

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CABLE JOINING
Splicing the Submersible Pump Cable onto the Motor
Waterboy submersible pump motors are a brushless, oil filled motor and require no earth cable. The
motor leads are marked 1,2,3 and need to be connected at the controller in this order, make note of
which number is spliced onto which wire before completing the splice.
Use only industry approved submersible power cable with a recommended conductor size of 4mm²
or larger.
An appropriate waterproof cable splice (jointing) kit includes crimp connectors to join the copper
wires, adhesive heat-shrink tubing, and instructions.
Always ensure the connectors are firmly crimped onto the electrical wire and no insulation is caught
inside.
Allow at least 10 –15 minutes before moving the join to ensure the heat shrink is set hard.
Splicing the Submersible Cable onto the Low Water Probe
The low water probe is spliced onto the submersible cable in the same manner as the power cable.
The low water probe is a normally closed (NC) switch with no operating polarity, there is no need to
keep track of the wire colors or apply labels.

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CONNECTING THE CONTROLLER
The Waterboy MPPT Solar Pump Controller must be mounted close to the solar array and pump, in a
secure and protected position. Mount the controller vertically using the mounting plate supplied, in a
ventilated area out of direct sunlight. This is often half way up the array post under the panels. 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 a DC isolator is
switched off, or the solar panels are unplugged prior to opening and working on the controller. Make
sure that all connections on the terminals are tight, with no loose wires before switching on.
Wiring
(See electrical diagrams overleaf)
1. Set the switch in the controller to the OFF position. This is the middle position on switches marked
SOLAR / BAT.
2. Insert the pump power cable through the largest gland in the bottom of the controller box, being
careful not to damage any components on the board.
3. Connect the 3 wires to terminals as indicated (1, 2, 3).
4. The low water circuit uses the normally closed (NC) terminals, COM1 and WH. If no sensor is being
used connect a link/jumper wire between terminals COM1 and WH.
5. Insert the low water cable through the smaller gland in the bottom of the controller box, being
careful not to damage any components on the board.
6. Connect the two wires to the terminals COM1 and WH.
7. The tank full circuit uses the normally open (NO) terminals, COM2 and TH. If no tank full/ pressure
switch is used, leave open.
8. Insert the tank full/pressure switch cable through the smaller gland in the bottom of the controller
box, being careful not to damage any components on the board.
9. Connect the two wires to the terminals COM2 and TH.
10. Connect the controller leads to the solar leads or isolator (if supplied).
11. 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 leads from the solar panels to the top of the
isolator, connect the leads from the controller to the bottom of the isolator.
12. Turn ON the solar array circuit breaker/isolator if one is being used with the system.
13. Ensure the pump is submerged before proceeding!
14. Switch the controller to ON (SOLAR); all indicator lights will turn on briefly and then go off except
for the “SYS” (System) light which should be green. After a few seconds the green “PUMP” light
will turn on and if all is connected correctly the pump will start.
15. The green MPPT light will flash on and off during pump operation.
16. Shutdown: always turn off the controller before switching off the main isolator switch.

10
Speed Adjustment
The speed control dial is used to reduce the flow of water produced by the pump, 0 –OFF, 10 –full
speed.
As some bores or wells recharge (refill) at a slower rate than the pump can discharge, it is common
for pumps to constantly switch on and off with the low water probe throughout the day. This cycling
can cause damage to your pump, and reduce your daily water output, due to the time wasted
switching back on. In these cases it is sometimes desirable to slow the pump down and pump all day.
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”.
NOTE: It is recommended that the speed not be reduced below 50% as this can cause low power
issues for the controller, if less flow is required then revise your system needs or bleed off some flow
back to the source.
Timer
The timer adjustment dial is used to extend the time it takes for the pump to wait before switching
back on after the low water probe is activated, 0 –instant back on, 30 –30 min delay.
The tank full circuit has no time delay and is instantly back on after the circuit is open again.
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.