Dankoff Solar Products SunCentric P User manual

Instruction Manual
Solar Powered Centrifugal Pump
for swimming pools, agriculture & more
Dankoff Solar Products, Inc
Santa Fe, NM USA
[phone]
[phone]
www.dankoffsolar.com
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TABLE OF CONTENTS
1 WARNINGS ......................................................................................................................................3
2 INTRODUCTION...............................................................................................................................4
3 INSTALLING THE SOLAR ARRAY...................................................................................................4
3.1 Location of the Solar Array................................................................................................................................ 4
3.2 Solar Array Mounting Rack ............................................................................................................................... 5
3.3 Solar Array Assembly Methods......................................................................................................................... 5
3.4 Orienting the Solar Array to Solar South .......................................................................................................... 6
3.5 Setting the Solar Array Tilt Angle...................................................................................................................... 7
4 ELECTRICAL INSTALLATION .........................................................................................................8
4.1 Controller, Junction Box, and Conduit .............................................................................................................. 8
4.2 Grounding and Lightning Protection ............................................................................................................... 11
4.3 Solar Array Wiring............................................................................................................................................ 13
4.4 Solar Array Disconnect Switch in the Junction Box ....................................................................................... 14
4.5 Junction Box (Controller Input) Wiring............................................................................................................ 14
4.6 Maximum RPM Setting.................................................................................................................................... 15
4.7 Motor Wiring Order for Correct Rotation......................................................................................................... 16
4.8 Pump Motor Bonding and Grounding ............................................................................................................. 16
4.9 Low-Water Probe for Dry-Run Protection....................................................................................................... 17
4.10 External ON/OFF Switching ............................................................................................................................ 17
4.11 Automatic Control For Full-Tank Shutoff ........................................................................................................ 19
4.12 AC Backup ....................................................................................................................................................... 21
5 SWIMMING POOL SYSTEMS.........................................................................................................22
5.1 The Need for Low-Friction Piping and Filtration............................................................................................. 22
5.2 Interface with Pool Cleaners and Pool Sweeps ............................................................................................. 23
6 PUMP INSTALLATION ...................................................................................................................24
6.1 Pump Location ................................................................................................................................................. 24
6.2 Piping................................................................................................................................................................ 24
6.3 Suction-Lift Applications .................................................................................................................................. 25
7 OPERATING THE PUMP................................................................................................................26
8 MAINTENANCE..............................................................................................................................27
8.1 Pump Maintenance.......................................................................................................................................... 27
8.2 Controller and Junction Box Maintenance...................................................................................................... 28
8.3 Solar Array Maintenance................................................................................................................................. 28
8.4 Electrical Wiring Maintenance......................................................................................................................... 28
Exploded View of Pump..................................................................................................................................................... 29
8.6 Parts List, Pump and Motor............................................................................................................................. 30
9 TROUBLE SHOOTING ...................................................................................................................31
9.1 If The Pump Doesn’t Run ................................................................................................................................ 31
9.2 Inspect The System......................................................................................................................................... 31
9.3 Test The System.............................................................................................................................................. 32
9.4 If The Pump Runs But Flow Is Less Than Normal......................................................................................... 33
10 WARRANTY................................................................................................................................34

1 WARNINGS
Failure to follow these instructions will void the warranty.
REFER TO THE SPECK PUMP OWNER’S MANUAL ENCLOSED, FOR SAFETY
WARNINGS AND ADDITIONAL INFORMATION
The installer is required to reset the “Maximum RPM” setting in the controller to position 2,
illustrated in Section 4.6.
Open circuit (no-load) voltage above 100V will destroy the controller. This may occur if the
wrong PV modules (solar panels) are used, or if the solar array is incorrectly wired. Measure
the array voltage before connecting to the controller. A “48V” (nominal) array should produce
an open circuit voltage around 75-90V under any daylight conditions. (See Solar Array Wiring,
Section 4.3)
Do not attempt to run the ETAPUMP Motor without the ETAPUMP controller.
Do not attempt to use ETAPUMP controller for any purpose other than ETAPUMP.
To be installed, connected and serviced by qualified personnel only. Ensure all power sources
are disconnected when making connections to this unit. Follow all appropriate electrical
codes. There are no user serviceable parts inside the motor or the controller.
Install proper system grounding for safety and lightning protection (See Section 4.2)
Do not touch the controller input or pump wires together to test for a spark.
Do not run the pump dry. Fill it at least half-way with water for testing.
Test the direction of motor rotation before installing the pump (clockwise looking at back of
motor). If direction is reversed, exchange the connection of any two of the three power wires
to the pump. (See Section 4.7)
When pump is stopped by a shadow or by action of float switch, it will restart after a 30–90
seconds.
SWIMMING POOL APPLICATIONS normally do not use a low-water probe or float switch.
Their terminals must be bypassed in the junction box. (See section 4.5)
Installation should be in accordance with local regulations and accepted codes of good practice.
This manual is the property of the pump owner.
Please give it to the owner or maintenance personnel when you are finished!
Request copies from your SunCentric supplier, or download from www.dankoffsolar.com
Copyright © 2003 by BERNT LORENTZ KG and DANKOFF SOLAR PRODUCTS, INC. All rights reserved
ETAPUMPis a registered trademark of BERNT LORENTZ KG
SUNCENTRIC P™ is a trademark of DANKOFF SOLAR PRODUCTS, INC.
Version 1.4 September, 2003
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2 INTRODUCTION
REFER TO THE SPECK PUMP OWNER’S MANUAL ENCLOSED
FOR SAFETY WARNINGS AND ADDITIONAL INFORMATION
Thank you for purchasing the Dankoff SunCentric P™ Solar Pool Pumping System. This system is
based on time-tested components and 20 years of solar pumping experience. Please follow these
instructions carefully. If you have any questions or problems, please call your Dankoff dealer, or call the
factory. We try very hard to make our products work in all cases.
Before you begin Check the model numbers of all the components of your system, and verify that
they are the items that you ordered. Also check against the SunCentric P specifications and performance
charts (end of this manual) to be sure the system is appropriate for your application.
Please read the labels on your pump motor and controller and enter the serial numbers here. This will
help you to obtain parts or service in the future.
PUMP MOTOR MODEL #_____ SERIAL #_____ 
 Please enter
CONTROLLER MODEL #_____ SERIAL #_____ 
 Please enter
SYSTEM # ________
3 INSTALLING THE SOLAR ARRAY
3.1 Location of the Solar Array
Sunlight is the “fuel” that drives a solar pump. Full solar exposure of the solar array is critical for the
performance of a solar-direct system.
Choose a location for the solar array that has unrestricted sun exposure through the day and through the
year. The array can be placed several hundred feet (100 m) or more from the wellhead. There will be no
loss of performance if the electrical wire is sized properly, but naturally, the cost of wire will increase
significantly.
WARNING A small shadow on the solar array will cause the pump to slow or stop completely.
Each PV module (panel) contains a series of solar cells (typically 36 or 72 cells). Every cell that is
shaded acts like a resistor, reducing the output of the entire array. Shading just one corner of the array
will reduce the power disproportionately, and may even stop the pump. Consider this when deciding
where to install the array.
To determine where shadows may be cast at any time of the year, you can survey the site with a Solar
Pathfinder®. This device is especially useful in forested areas or wherever there are obstructions nearby.
It is available directly from Solar Pathfinder (USA) Tel. & fax [phone], www.solarpathfinder.com.
Place the bottom edge of the array at least 2 feet (.6 m) above ground to clear rain spatter, growing
vegetation and snow. Keep in mind that trees and perennial plants will grow taller over the years.

3.2 Solar Array Mounting Rack
WARNING All parts of your mounting structure must be engineered for wind resistance, ease of
adjustment, and safety.
Follow the rack manufacturer’s instructions that are packed with your rack.
WARNING Use extreme caution when assembling
the array above your head. You will work with a large
and heavy assembly and unpredictable wind. The use of
ladders can be dangerous. It is best to assemble a
platform using a strong scaffold assembly (the
temporary platform system that is used for building
construction). A scaffold system can be rented from a
local supplier.
Solar Tracking 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 pumping volume by 40-50%. (It
is much less effective in winter and in cloudy weather.)
A tracker is an option with SunCentric P Systems.
PHOTO Typical assembly of a solar array on a passive
(non-electric) tracker. The tracker pipe was extended to
about 10 feet (3m), by welding it to a larger pipe. The
array was assembled and wired on the ground, then
lifted and lowered onto the pole with the help of a
backhoe and chain. Wire is single-conductor type USE
(outdoor rated). See how the wire is looped. This allows
it to shed water, and to flex easily as the tracker swings
East-West. Wires enter the conduit through a “weather
head” fitting (enlarged).
3.3 Solar Array Assembly Methods
WARNING Use extreme caution when assembling the array above your head. You will work with a
large and heavy assembly and unpredictable wind. The use of ladders can be dangerous.
There are two ways to install the solar array. See PHOTO GALLERY for examples.
1. Assemble the array on the ground, wiring and all, then lift the entire assembly onto the pole or
roof. A system of 300 watts or more may require the assistance of a backhoe, boom truck or
crane to lift it over the pole.
Assemble the array piece-by-piece on the pole. If the pole is higher than about 6 feet (2m), it is best to
construct a temporary platform, like a scaffold assembly commonly used in building construction). A
scaffold system can be rented from a local supplier.

3.4 Orienting the Solar Array to Solar South
For full performance, your solar array must be oriented within 10° of true (solar) south. Depending on
your location, a compass reading may show an error of as much as 20°. To correct this discrepancy,
apply the magnetic declination for your region. Many regional maps indicate the magnetic declination. If
you don’t have a compass but can see your shadow and know the time of day, use this Sun Compass.
Sun Compass™
For the USA (lower 48 states) and other 25° to 55° North latitude regions.
Find True South quickly and accurately using only your shadow. No magnetic compass needed!
Sun Compass Instructions
1. Draw an arrow from Month dot to intersection of your Standard Time and Latitude.
(The gray line is an example: August, 2 PM at 40° N lat.)
2. Stand and face your shadow.
3. Hold this page horizontally.
4. Point the arrow that you drew to center of your shadow.
5. Sun Compass now indicates the four directions.
Sun Compass™is available for the following latitudes:
1. U.S.A. (25° to 55°) – shown here 3. Equatorial (20° N to 20° S)
2. Northern (50° N to 70° N) 4. Southern (10° S to 40° S)
To obtain reproduction rights, contact: John Veltman PO Box 23533, Santa Fe, NM 87502 USA
North
Aug
8 A
M
9AM
10AM
11AM 1PM
2 PM
4PM
3PM
Jul
Jun
Apr
Mar
Jan
Feb
May
Oct
Nov
Dec
Sep
2 P
M
3PM
4PM
10AM
9AM
8 A
M
11AM
South
6AM
7AM 5PM
6PM
East
© 1996 b
y
John Veltman
50°
40°
30°
West

3.5 Setting the Solar Array Tilt Angle
Some solar array racks are adjustable to a desired angle, to accommodate both the location and the
season. We offer these choices for seasonal management.
1. YEAR-ROUND COMPROMISE (no seasonal adjustment) Set the angle equal to the latitude of
the location and “forget it”. This is good if the pool is to be used year-round.
2. SEASONALLY ADJUSTED This is good if you want to maximize performance for both the winter
and the summer-half of the year. It is sufficient to perform the adjustment only twice per year, at
the spring and autumn equinoxes, to the angles indicated below. For central USA, daily water
production will be increased by about 8% in summer, 5% in winter compared to option 1. There is
less advantage in a cloudier climate. If adjustment is difficult or is likely to be forgotten, this is not
a good option.
3. SUMMER USE For use only during summer half of the year, set the array to the seasonal
angle shown below, and “forget it”. The pump will function in the winter, but at a substantially
reduced pumping rate.
Ideal angles (from horizontal) are: Summer optimum = latitude -15° Winter optimum = latitude + 15°
Solar Array Tilt Angles by latitude
Summer Winter Year-Round
Location (examples) Latitude Tilt Tilt Compromise
Southern Canada 50° 35° 65° 50°
Upper Third of USA 45° 30° 60° 45°
Middle Third of USA 40° 25° 55° 40°
Lower Third of USA 35° 20° 50° 35°
Central Mexico 20° 5° * 35° 20°
* 0-25° latitudes Apply a minimum tilt angle of 10°, or dust and debris will accumulate.

4 ELECTRICAL INSTALLATION
4.1 Controller, Junction Box, and Conduit
WARNING To be installed, connected and serviced by qualified personnel only. Ensure all power
sources are disconnected when making connections to the controller. Follow all appropriate
electrical codes. There are no user serviceable parts inside the motor or the controller.
System Wiring Diagram If your pump was purchased as part of a pre-packaged system, a System
Wiring Diagram should be attached at the back of this manual.
Location If the solar array is to be located more than about 100 feet (30m) from the pump, place the
controller close to the solar array, not the pump. This will reduce the risk of lightning damage.
Explanation — The controller’s input circuitry is more sensitive to surges than its output. It is safest to
minimize the length of the input wiring.
Protection from solar heat Electronic devices are most reliable when they are protected from heat.
The ideal location is in the pump room. If there isn’t a pump room with adequate space, mount the
controller in the shade of the mid-day sun. If the controller is to be mounted at the solar array, an ideal
location is directly under the array, on the north side of the mounting pole. If shade is not available, cut a
piece of sheet metal and bolt it behind the top of the controller. Bend it over the controller to provide
shade. This is especially important in extremely hot locations.
Location of controller For outdoor installation, mount the controller vertically to shed rainwater. It is
preferable to mount it ON THE NORTH SIDE of a pole or other structure, to help reduce solar heating.
This may also allow easiest access without hitting your head on the lower (south) edge of the array.
Junction box A pre-wired junction box is included with your system. The junction box terminals will
handle pump wires as large as #6 (13 sq. mm). If large wires cannot be accommodated easily in the box,
you can join them to smaller wires in the junction box. #12 (4 sq. mm) or larger is acceptable for this very
short length. Do NOT remove terminal screws. If the key to the junction box gets lost, it can be opened
with a screwdriver.
ON/OFF switch If the controller and junction box is not to be installed near the pump, and an ON/OFF
switch is required near the pump, or if a timer, float switch, or any other external on/off control is
required, refer to Section 4.10, External ON/OFF Switching.
Mounting the controller and junction box to a pole See photos on the following page. The controller
can be mounted onto the solar array support pole using materials available from your local electric
supply store. The best mounting hardware is “slotted strut” (Unistrut® or equivalent). This makes a
strong assembly that is easy to adjust. In USA, these materials are commonly available from electric
suppliers.
Other methods of mounting to a pole:
1. Make “U-bolts” from threaded steel rod. You may need to drill additional holes in the junction box.
Seal unused holes with a permanent sealant.
2. Attach a metal plate to the pole and bolt the boxes to the plate.
3. Drill and tap holes in the pole, drill matching bolt holes (centered) in the boxes.
Electrical conduit is recommended Electrical conduit (pipe) protects outdoor wiring from the
weather, from human activities, and from chewing animals. If you don’t use conduit, use strong, high-
quality outdoor cable. Where cables enter the junction box, install sealed strain-relief cable clamps.

Keep the controller and junction box sealed Unused holes must be sealed against animals, insects,
water and dirt. Each hole is supplied with a rubber plug that can be kept in place for this purpose.
CAUTION Loose connections are the most common cause of system failures.
Pull on each connection to confirm that it is secure.
PHOTO GALLERY
Illustrated on the next pages is a 300-watt solar-direct system with a pole mount. The pump controller
and the junction box are installed on the pole. The array is set at summer tilt angle. The controller is
mounted on the north side of the pole, directly under the array. This shades it from the hot mid-day sun.
This system was installed by students in a solar water pumping class.
Photos courtesy of Solar Energy International, Carbondale, CO, USA

Bare ground wires bond the PV modules to
the controller enclosure, and continue down
to the ground rod. Flat braid is shown at the
array. It is flexible and eliminates need for
lugs.
slotted strut (Unistrut® or
equivalent), cut to the width
of the box.
conduit clamp to fit slotted strut
hose clamp
Typical assembly of the controller and
junction box on the solar array mounting
pole. Boxes are secured using slotted strut
and conduit clamps.
Mount the controller on the north side of
the pole to reduce solar heating.